Simplified local infill size optimization for FDM printed PLA parts

Abstract

The great advantage of additive manufacturing is the fact that hollowed parts with a given infill can be created. However, the standardized commercial slicer software offers a uniform infill pattern creation solution. In engineering practice, the manufactured parts are functional, therefore the appropriate load bearing capacity is mostly mandatory. In this paper a simplified local infill size optimization method has been presented. Based on a Finite Element Analysis the local density of the pattern can be adjusted, according to the emerged local stresses. The results show that independently of the pattern type, if the scaling was applied, the mechanical resistance was improved to the same extent. In case of the worst-performing uniform pattern, 84% improvement in mechanical resistance was achieved with the optimization. In addition, an FDM printing problem has been highlighted, which must be eliminated if the proposed method is used.