ORE Open Research Exeter

TITLE
Optimising the FDM additive manufacturing process to achieve maximum tensile strength: a state-of-
the-art review

AUTHORS
Gordelier, TJ; Thies, P; Turner, L; et al.

JOURNAL
Rapid Prototyping Journal

DEPOSITED IN ORE
16 August 2019

This version available at

http://hdl.handle.net/10871/38357

COPYRIGHT AND REUSE

Open Research Exeter makes this work available in accordance with publisher policies.

A NOTE ON VERSIONS
The version presented here may differ from the published version. If citing, you are advised to consult the published version for pagination, volume/issue and date of
publication
Optimising the FDM additive manufacturing process to
achieve maximum tensile strength:
A state of the art review.

T.Gordeliera,∗, P.R.Thiesa , L.Johanninga , L.Turnerb

a Renewable Energy Research Group, University of Exeter, Penryn Campus, Cornwall, UK,
TR10 9FE.
b 3D Kernow, Concept Shed, Falmouth, UK, TR11 3EX.

Abstract
Additive manufacturing or ‘3D printing’ is a rapidly expanding sector and
is moving from a prototyping service to a manufacturing service in its own
right. With a significant increase in sales, Fused Deposition Modelling (FDM)
printers are now the most prevalent 3D printer on the market. The increase in
commercial manufacturing necessitates an improved understanding of how to
optimise the FDM printing process for various product mechanical properties.
This paper seeks to identify optimum print parameters for the FDM process
to achieve maximum tensile strength through a review of recent studies in this
field. The effect of the governing printing parameters on the tensile strength of
printed samples will be considered, including: material selection, print orienta-
tion, raster angle, air gap and layer height.
Key findings include material recommendations, such as the use of emerging
print materials like polyether-ether-ketone (PEEK) to produce samples with
tensile strength over 200% that of conventional materials such as acrylonitrile
butadiene styrene (ABS). Amongst other parameters it is shown that printing in
the ‘upright’ orientation should be avoided (samples can be up to 50% weaker in
this orientation) and air gap and raster width should be concurrently optimised
to ensure good ‘inter-raster’ bonding. The optimal choice of raster angle depends
on print material; in ABS for example, selecting a 0◦ raster angle over a 90◦
angle can increase tensile strength by up to 100%.
The paper conclusions provide researchers and practitioners with an up to
date, single point reference, highlighting a series of robust recommendations to
optimise the tensile strength of FDM printed samples. Improving the mechanical
performance of FDM printed samples will support the continued growth of this
technology as a viable production technique.
Keywords: FDM, tensile strength, raster angle, ABS, PLA, print orientation,
air gap.

∗ Correspondingauthor
Email address: [email protected] (T.Gordelier)

Preprint submitted to Journal of LATEX Templates August 16, 2019

 1. Introduction

Additive manufacturing (AM) is a rapidly expanding sector and is antici-

pated to continue growing as detailed in Figure 1 [1]. The advantages it repre-
sents over conventional manufacturing technologies have led to a rapid up-take
5 across many sectors. This cross sector applicability is also clearly demonstrated
in Figure 1.
Historically AM technology was utilised for prototype production, but in-
creasingly it is being seen as a production technique in its own right [2]. A
2017 global review of over 900 AM users found that whilst 34% and 23% of re-
10 spondents use AM for prototype and proof of concept development respectively,
a surprising 22% already use it for production purposes [3]. This increase in
production printing has led to great interest in the material properties of AM
products, with manufactures keen to demonstrate to their customers that their
products can meet certain standards. Despite the apparent need, to date, no
15 specific material property tests are available for AM products as will be discussed
in Section 3. To add to this uncertainty, many different printing technologies
are available and within each technology group there are numerous printing pa-
rameters and material options available for any given printer. This leads to a
large variation in the physical properties of AM products.
20 The range of printing technologies available is detailed in Figure 2 and
demonstrates that, in 2017, Fused Deposition Modelling (FDM) is the most
common technique. This study also finds that plastics are the most common
printing material, utilised by 88% of respondents. Given this is the most com-
mon printing technique, it will form the focus of the paper here and the FDM
25 printing process will be briefly summarised in Section 2.
Many studies have been conducted to consider the impact of printing pa-
rameters on the quality of the end product for FDM printing. To date, no
one paper is available that summarises this large body of work, and sets out key
printing parameters to optimise component strength. This paper therefore seeks
30 to amalgamate these studies and provide a useful reference for anyone hoping to
optimise the FDM printing process to achieve maximum tensile strength of their
printed components. Additive manufacturing is a rapidly developing technology
and as such, this paper focuses on recent studies from 2014 onwards. Where a

Abbreviations: ABS: Acrylonitrile butadiene styrene AM: Additive manufacturing DE:

Differential evolution CAD: Computer aided design COV: Coefficients of variation FDM:
Fused deposition modelling FE: Finite element FEA: Finite element analysis FLM: Fused
layer modelling GMDH: Group method of data handling MIA: Multi-layered iteration PEEK:
Polyether-ether-ketone PC: Polycarbonate PLA: Polylactic acid RepRap: Replicating rapid
prototyper SEM: Scanning electron microscope SLA: Sterolithography STL file: Stereolithog-
raphy file - often used to export CAD files in preparation for AM printing TPE: Thermoplastic
elastomer UTS: Ultimate tensile strength XRD: X-ray powder diffraction

2
 Figure 1: U.S. 3D printing market forecast by year, 2014-2025. Summarised from [1].

study is felt to be particularly relevant however, some earlier findings will be

35 included.
Within this paper, firstly, the adopted test methods will be reviewed in
Section 3, the results will then be highlighted in Section 4, and reasons for
the observed variation in strength will be covered in the Discussion, Section
5. Finally, Conclusions in Section 6 will summarise the optimal FDM printing
40 parameters to maximise component tensile strength.

2. The FDM process

Before detailing the FDM process, it should be noted that this process is
also referred to as Fused Filament Fabrication (FFF). The term FDM was trade-
marked by Stratysys Inc. and hence an alternative name, FFF, was developed
45 by some users to avoid conflict. The two names refer to identical technoloy.
As outlined in Section 1, FDM printing is one of the most widely adopted
forms of AM and many publications outline the printing process in detail; a

3
 Figure 2: 3D printing technologies adopted by respondents, from a 2017 global survey of 900+
users. Summarised from [3].

selection of these are included for reference [4, 5, 6, 7]. A detailed explanation
of the physical phenomena behind the FDM printing process is also provided
50 by [8]. In this section, a brief summary of the process will be provided with
reference to Figure 3 which outlines the key components of a FDM printer. The
first step of printing a FDM component is to develop a computer aided design
(CAD) model of the component. The CAD model is commonly exported as
a stereolithography (STL) file which is then ‘sliced’ by specialist 3D printing
55 software and read by the printer to print the component in a series of ‘sliced’
layers. A spool of printing filament is drawn through the extruder head, which
heats the filament to a semi-molten state. It is then forced through an extrusion
nozzle and onto the printer build platform. The extruder head (or the build
platform) is able to move around in the X-Y plane creating a 2D slice of the
60 required part. Once the first layer is complete, the extruder head (or the build
platform) will move in the Z direction, to enable a second layer of 2D material
to be applied on-top of the first. The semi-molten state of the material allows
adjacent layers to fuse together forming the 3D solid layer by layer. Some 3D
structures may have overhangs, and as such require a support structure during
65 the printing process. For this there are two main options: The FDM printer
can print the support structure (or ‘scaffolding’) in a more fragile state so that
it can be clipped off once printing is complete. Alternatively, some printers
use a second nozzle utilising a different material to print the support structure
concurrently with the main component. The support structure is then removed
70 once printing is complete (often the support structure material is soluble for
example).

4
 Figure 3: Key components of a FDM printer. Movement is achieved in the x, y and z direction
by either movement of the extrusion head (purple arrows), movement of the build platform
(green arrows) or a combination of the two e.g. x and y direction achieved by movement of
the extrusion head and z direction achieved by movement of the build platform. Developed
from original image by [6].

A further progression of the commercial FDM printer came through the

development of the ‘RepRap Printer’, short for replicating rapid prototyper.
This printer, based on FDM technology, is essentially self-replicating and a
75 ‘parent’ printer can print out a significant proportion of the parts required
to build a ‘child’ printer, with the remaining parts being widely and cheaply
available. The ‘RepRap’ project started in 2004, with the first ‘child’ machine
manufactured at Bath University in 2008 [9]. The design of the printer is open
source and free to access, with many variants available; this has led to very low
80 production costs and correspondingly large global uptake. The high prevalence
of these printers further adds to interest on how to optimise the printing process,
and some of the studies considered later in this paper will look at optimising
the tensile strength of ‘RepRap’ printed components.
With the basics of FDM printer technoloy explained, the next section sets out
85 the different methodologies applied by the sector to test FDM printed products
for tensile strength.

3. Applied methodologies

To date, no specific guidance is available to quantify the tensile strength of

AM products, and most studies have referred to existing tensile strength tests
90 for materials such as polymers or composite materials. It was anticipated that
a recent publication from DNV GL, ‘DNVGL-CF-0197 Additive manufacturing

5
 Figure 4: Dimensions for specimen 1A of ISO 527-2-1996 standard for the determination of
tensile properties of moulding and extrusion plastics [12].

- qualification and certification process for materials and components’ [10], may
help to bridge this lack of guidance, however this publication refers to generic
paths for qualification and cites a range of existing test methodologies rather
95 than specifically creating a new standard for AM.
Despite this lack of guidance, many studies have investigated the effect of nu-
merous printing parameters on the final printed product. Within these studies
a range of methodologies have been adopted to quantify the tensile strength of
printed samples. The approaches fall into one of two categories: The ‘Hourglass’
100 type specimen, utilising a dumbbell or hourglass shaped test piece and covered
in Section 3.1, and the alternative ‘Rectangular’ type specimen, utilising a rect-
angular shaped test piece and covered in Section 3.3. The following sections will
review the two broad approaches adopted by the majority of studies discussed
here and highlight potential weaknesses with these approaches.

105 3.1. ‘Hourglass’ tensile test methodology

There are two key test standards that have been widely adopted by the sector
utilising the ‘hourglass’ type tensile test specimen, these are the ASTM D638
Standard test method for tensile properties of plastics [11] and the equivalent ISO
standard, BS EN ISO 527-2-1996 Plastics. Determination of tensile properties.
110 Part 2: Test conditions for moulding and extrusion plastics [12]. The ISO 527
standard has 5 parts, with part 1 focusing on the general testing principles and
the remaining 4 parts identifying testing methodologies for a range of different
plastics. Part 2 represents an ‘hourglass’ type specimen as detailed in Figure 4
and is the most widely adopted methodology of the ISO 527 standard in the AM
115 work reviewed. The ASTM D638 standard is more flexible in terms of sample
geometry than the more prescriptive ISO 527-2, with a range of test specimens to
choose from. However, both standards adopt broadly similar sample dimensions.
As this paper is focused on the FDM printing approach, those studies looking
to investigate FDM printed samples will be highlighted. Of these studies the
120 ASTM D638 approach is adopted by [13, 14, 4, 15, 16, 17, 18, 19, 20] and
[6]. Indeed a review paper by [21] demonstrates this is a popular approach for
reviewing the tensile strength of products from a range of rapid prototyping
techniques, not just FDM. The alternative, but similar ISO 527-2 approach is

6
 Figure 5: FEA model demonstrating the equivalent stress in an ISO 527-2 specimen 1A
(dimensions as detailed in Figure 4). Model is subject to a tensile load of 5,000N. The peak
stress in red occurs adjacent to the bend radii.

adopted by [22, 23, 24, 25, 26] and [27]. The ISO 527-3 approach [28] (specifically
125 for films and sheets) also utilises an ‘hourglass’ shaped sample and is utilised
by [27].
There are three further studies that have adopted an ‘hourglass’ type tensile
test specimen, though have not specifically followed either the ASTM D628 or
the ISO 527-2 test methodology. These are [23, 29] and [30].
130 Although the majority of these studies report valid results when adopting the
above approach some issues with this type of methodology have been reported
by [7] and others, and will be highlighted below.

3.2. Issues with ‘hourglass’ methodology

The principal of the ‘hourglass’ specimen is that the failure occurs in the
135 gauge length of the sample where the sample is thinnest. However it has been
noted in some studies that premature failures of some samples have occurred at
the bend radius, outside of the gauge length of the specimen. A simple finite
element analysis (FEA) demonstrates that the geometry of the sample leads to
stress concentrations at these points, as detailed in Figure 5.
140 The issue of early sample failures is investigated by [31] who originally in-
tended to follow the ASTM D638 standard to characterise the properties of FDM
printed ABS. On preliminary testing the samples were found to fail prematurely
on the bend radius due to these stress concentrations. This study highlights that
the issue is compounded by the FDM manufacturing process where the radii is
145 approximated by the termination of raster lengths as highlighted in Figure 6.
This issue is also raised by [17], who in earlier work had adopted the ASTM
D638 methodology [13]. However, during an investigation into the effects of
layer parameters on the tensile strength of FDM printed ABS [17] also observe
premature sample failures on the radii of the samples. This research identifies a
150 particular issue for thin specimens printed in certain orientations. To obtain re-
liable results across the range of samples under investigation this study reverted
to rectangular shaped geometry, nominally based around the sample dimensions
of the ASTM D638 ‘hourglass’ shape.

7
 Figure 6: Tensile tests conducted by [31] demonstrate issues with premature shear failure at
the sample radius due to stress concentrations developing. Image replicated from [31].

Further to these studies [14] also uses the ASTM D638 approach for a com-
155 parative study of ABS and PLA specimens printed using a ‘RepRap’ type
printer. This study states that “many specimens broke outside of the gauge
length due to assumed stress concentrations in the regions changing geometry”.
Despite observing this during the experimental phase, the data from these in-
vestigations were reported as valid results.
160 It is of concern that further studies utilising the discussed methodologies do
not interpret an issue with the obtained results if the samples fail outside of
the gauge length. Only a limited number of studies publish images of failed
specimens which makes it challenging to establish the validity of results. Help-
fully, a study by [25] utilising the ISO 527-2 approach to characterise properties
165 of FDM printed ABS samples publish an image demonstrating a selection of
failed specimens, this is replicated in Figure 7. Of the 15 specimens detailed
only three demonstrate fracture within the gauge length of the samples, with
the remaining failures occurring at, or very near, the radii. Again, it appears in
this study that all these samples were included as valid results.
170 A single example image of a failed specimen is published by [27] who utilise
an ‘hourglass’ specimen to review a range of materials from both FDM and SLA
printing. This image also demonstrates a failure at the radius of the samples
but no reference is made to this being a rejected sample or out of scope.
For both of these examples, these out of range failures could be considered
175 a ‘worst-case-scenario,’ underestimating the true strength of the material. In-
clusion of these results in the reported data should therefore not lead to over
optimistic conclusions and can perhaps be justified on this basis. However, it is
surprising to see no discussion of this in the presented reports.
Some studies include details of samples that have successfully broken within
180 the sample gauge length including [15, 29, 18] and [6]. It is a valuable contri-
bution that all the publications discussed above do provide details on the failed
samples, whether deemed ‘successful’ or not. Many of the studies however, do

8
 Figure 7: Results published in [25] highlighting the range of failure modes when utilising ISO
527-2 to investigate the characteristics of FDM printed ABS. The samples were printed with
a range of raster angles at the following orientations: (a) Horizontal orientation. (b) Vertical
orientation. (c) Perpendicular orientation. All samples excluding row (a) H-60, H-90 and
H-45 demonstrate failure at the sample radius. Image replicated from [25].

not publish this information which raises concerns regarding whether early fail-
ures occurred at the sample radii and if so, how this could affect the validity of
185 the results.
Given these concerns regarding the ‘hourglass’ type specimens, alternative
methodologies are discussed below.

3.3. Alternative methodologies

The main issue with the ‘hourglass’ shaped specimen is the stress concen-
190 tration around the radii due to the sample geometry. This issue is intensified
by the FDM technique which essentially lays the material in lines (often refer-
eed to as ‘roads’ or ‘rasters’) resulting in manufacturing discontinuities at these
radius points. It is therefore helpful to refer to testing standards for other ma-
terials that have similar anisotropy in their formation, such as fibre reinforced
195 composites. Some studies have looked to these standards for guidance.
The equivalent standards are (i) BS EN ISO 527-5:2009 Plastics. Determi-
nation of tensile properties. Part 5: Test conditions for uni-directional fibre-
reinforced plastic composites [32] and correspondingly (ii) ASTM D3039-17
Standard test method for tensile properties of polymer matrix composite ma-
200 terials [33]. Both these standards adopt rectangular shaped specimens and
therefore avoid the issues created by the radii of the ‘hourglass’ specimens.
There are however, far fewer examples of these standards being adopted in
the literature. The ASTM D3039 standard is utilised by [31] when compar-
ing the tensile strength of FDM manufactured ABS parts directly to injection
205 moulded parts. It is also adopted by [34] and [5] to investigate the effect of vari-
ous printing parameters on the tensile strength of FDM printed ABS. Composite
testing experts Intertek suggest utilising the ASTM D3039 standard instead of

9
 the ‘hourglass’ ASTM D638 standard for AM applications suggesting it is “rec-
ommended for highly oriented and/or high modulus fibre reinforced polymer
210 composites” [35].
There is limited adoption of the ISO 527-5 standard, although it is referred to
by [36] who propose a methodology for single layer AM specimens and state that
this standard is applicable due to “structural analogies” between AM specimens
and fibre-reinforced plastics.
215 Having considered the various approaches adopted by the sector for quan-
tifying the tensile strength of samples, the next section will detail the results
obtained across the various studies.

4. Tensile strength optimisation results

4.1. Material selection

220 A range of materials can be utilised with FDM printing, and new materials
are continually being added to the available selection. Two of the most common
materials utilised at the time of writing are ABS and PLA. [26] utilise the ISO
527 approach adopting the specimen dimensions in Figure 4 to investigate the
comparative strength of these two samples and conclude that PLA demonstrates
225 1.2 to 1.5 times the yield strength of ABS. This study also consideres the specific
strength of the specimens, which takes into account the density of the specimen
in addition to the strength. Again, PLA demonstrates the strongest response
with a specific strength 1.1 to 1.3 times that of ABS.
The ‘RepRap’ printer technology introduced in Section 2 is utilised by [14]
230 who also investigate the relative merits of PLA and ABS, this time utilising the
ASTM D638 standard. Across the range of variables tested PLA is shown to
have twice the tensile strength of ABS. The study also discusses the relative
strength of these parts in comparison to commercial 3-D printers and concludes
they can produce parts of comparable strength. However, in comparison to in-
235 jection moulded specimens, the study concludes that although PLA can achieve
similar strength, ABS parts are generally weaker than the injection moulded
alternatives.
ABS is compared to another material, polycarbonate (PC), by [6] using
the ASTM D638 methodology. Across all printing parameters investigated PC
240 samples demonstrates significantly higher tensile strength at break than the
ABS samples. The strongest PC sample was manufactured with an ‘on-edge’
print orientation (described further in Section 4.3) and a ±45◦ raster angle. The
tensile strength of this sample at break was 1.9 times that of the equivalent ABS
sample.
245 A comparatively newer material to the market polyether-ether-ketone (PEEK)
is compared to ABS by [29] utilising small 75mm long ‘hourglass’ tensile test
specimens. This study concludes that the tensile strength of PEEK samples
is on average 108% higher than ABS. The study also suggests that further im-
provements could be made to the mechanical strength of PEEK samples through
250 further optimisation of the printing techniques adopted for this newer material.

10
 In addition to alternative materials, some studies have considered the use
of additives with standard materials to develop composites in order to improve
mechanical properties. A detailed review of FDM fibre reinforced polymers
is provided by [8] who summarise numerous studies that investigate the po-
255 tential advantages of these composite materials. This review concludes that
continuous fibre reinforced composites are significantly stronger than discon-
tinuous fibre composites, achieving strength comparable to aluminium in some
instances. The direction of loading also plays a significant role, with loading
perpendicular to the raster beads resulting in much weaker components. The
260 concept of anisotropy in FDM printed parts will be further explored in Sections
4.2 and 4.3.
One such example of a composite study is conducted by [15] who compare
standard ABS to ABS with 5 wt.% discontinuous jute fibre (Cyclolac , GE ®
ABS resin), ABS with 5 wt.% titanium dioxide (TiO2 ) and an ABS polymeric
265 blend with 5 wt.% of a thermoplastic elastomer (TPE). Utilising the ASTM
D638 standard the tensile strength of each variant is investigated and only the
ABS with TiO2 is shown to improve the tensile strength of the standard ABS
samples, increasing the UTS by 13.2% on average. The jute composite and the
TPE blend actually reduce the UTS by 9% and 16% respectively. This work
270 is continued in a further study, [37], which focuses on ABS polymer matrix
composites and polymer blends. Although this study demonstrates that some
of these additives can lead to a reduction in sample anisotropy, this comes at
the expense of UTS with a reduction in overall sample tensile strength. For
further studies relating to FDM fibre reinforced composites see [8].
275 Even within each material classification there are variations between the
specific feedstock utilised for printing and [38] consider the tensile strength of
specimens printed from a range of different coloured PLA filaments (white,
blue, grey, black and natural). Utilising the ASTM D638 standard, this study
demonstrates that natural PLA (with no added dye) has the highest tensile
280 strength whilst grey PLA has the lowest. On average, the samples printed with
natural PLA have an ultimate tensile strength 12% higher and a yield strength
14% higher than the grey samples. Blue, white and black PLA samples have
tensile strengths scattered between these two extremes.
To summarise the large number of studies considering the effect of material
285 selection on component strength, Table 1 has been included.
In addition to material selection, numerous printing parameters can be varied
to optimise the printing process and the following sections will review these.

4.2. Raster orientation

The most common printing variable to be investigated to optimise FDM
290 printing is the raster angle. Raster angle denotes the angle at which the rasters,
or roads, are laid during the construction of each layer during the FDM process
as detailed in Figure 8. Many printers default to a ± 45◦ angle however this
variable can usually be controlled to either print at one angle or at an alternat-
ing angle for each layer. A total of 13 studies have been identified that have

11
Table 1: Summary of studies investigating the effect of material selection on printed sample
tensile strength. Table notes: *Denotes studies utilising ‘RepRap’ printer technology

Author(s) Variables Material for Notes

considered max tensile
strength
Ebel et al. 2014 ABS and PLA PLA PLA 1.2 to 1.5
[26] times stronger
than ABS.
Tymrak et al. ABS and PLA PLA PLA twice the
2014 [14]* tensile strength
of ABS averaged
across all sample
variations.
Cantrell et al. ABS and PC PC PC 1.9 times
2017 [6] strength of ABS.
Wu et al. 2015 ABS and PEEK PEEK PEEK 108%
[29] stronger than
ABS.
Torrado Perez et ABS, ABS with ABS with TiO2 TiO2 increased
al. 2014 [15] jute, ABS with strength by
TiO2, ABS with 13.2%. All other
TPE additives re-
duced the tensile
strength.
Wittdrodt et al. PLA filament Natural (12% Related to hav-
2015 [38]* colour (natural, higher UTS ing the lowest
white, blue, than grey) crystallinity.
black and grey)
Breken et al. Review of fibre Nylon with 18% Continuous fi-
2018 [8] reinforced poly- carbon fibre bre composites
mers strongest.

12
 Figure 8: Raster angle definition. Blue lines identify raster pattern and large black arrows
identify direction of tensile loading. In this paper, raster angle will be defined from 0◦ being
fully aligned with the tensile loading direction to 90◦ being perpendicular to the tensile loading
direction.

295 considered the raster orientation and will be detailed below in sub-sections re-
lating to printing material. Conventional printing practice generally utilises a
solid outer skin filled with an internal structure to speed up printing time and
minimise material use. This is specified by the pattern of the structure and a
% infill value, with machines often defaulting to 20% infill. However, for the
300 experimental investigations reported below, unless otherwise stated, the sam-
ples are printed at 100% infill i.e. solid blocks. Although this is not normally
adopted in general printing practice, this ensures that it is the material and
printing parameters that are investigated as opposed to the print construction.

4.2.1. Raster angle for ABS

305 Four raster angles are considered by [31]: 0◦ , ±45◦ , 0◦ /90◦ and 90◦ utilising
the ASTM D3039 approach. This study concludes that the 0◦ angle (where
the tensile strength is carried along the direction of the raster) has the highest
tensile strength, approaching twice the strength of samples printed with a 90◦
angle. The specimens printed with ±45◦ and 0◦ /90◦ raster angle demonstrate
310 similar tensile strength, higher than the 90◦ specimens and lower than the 0◦
specimens.
A complex statistical approach is utilised by [22] to investigate the effect
of numerous printing parameters on the material properties of ABS samples
utilising ISO 527-2 specimens. Three raster angles are investigated, 0◦ , 30◦ and
315 60◦ . The paper does not provide a definition of the terminology used so it is
assumed that the angles are specified in accordance with the majority of other
studies i.e. as in Figure 8. Although many variables are considered, the samples
with the highest UTS are printed with a raster angle of 60◦ . Reasons for this
finding will be addressed in the Discussion, Section 5.2.
320 A similar study is conducted by [34] who use ASTM D3039 to consider raster
angles of 0◦ , 45◦ , 90◦ and ±45◦ in FDM ABS samples and also compare these
to the tensile strength of injection moulded parts. Here, the highest tensile
strength is achieved with a 0◦ raster angle followed by ±45◦ (which failed at

13
 75% the strength of the 0◦ samples). On average, the 0◦ specimens obtain
325 a tensile strength of 94.8% compared to an injection moulded equivalent. The
study also considers the tension-tension fatigue performance of the samples with
±45◦ demonstrating the highest cycles to failure.
The work by [25] utilises ISO 527-2 to investigate the effect of five different
raster angles (0◦ , 30◦ , 45◦ , 60◦ , 90◦ ) on a range of mechanical properties. This
330 study also considers the effect of print orientation on these mechanical properties
which will be explained in Section 4.3. For standard printing orientations (flat or
‘on-edge’) the 0◦ raster angle demonstrates the highest tensile strength. For the
upright print orientation (which would not usually be adopted in conventional
printing practice) the 90◦ raster angle demonstrates the highest tensile strength.
335 A further study by [39] utilises a multi-layered iterative (MIA) group method
of data handling (GMDH) algorithm to investigate optimal parameters for FDM
printing applying differential evolution (DE). Experimental results applying the
ISO 527-2 process are utilised to verify the mathematical model. Pre-tests are
conducted to inform the algorithm and the full suite of tests consider two raster
340 angles 0◦ and 90◦ . The developed algorithm then calculates the optimal process
parameters for tensile strength. Many different variables are investigated and
although raster angle is shown not to be the most significant factor influencing
tensile strength, the optimal raster angle for tensile strength is found to be 50◦ .
A finite element (FE) model of FDM specimens is developed by [16] who
345 compare FE results to physical testing following the ASTM D638 test procedure.
Three raster angles are considered 0◦ , 45◦ and 90◦ . Although summary data
of results is not provided in the paper, graphical results of the physical tests
clearly demonstrate the maximum UTS is obtained with a raster angle of 0◦ .
Further investigations are conducted by [5] who utilise the rectangular ASTM
350 D3039 specimens to investigate the strength of a range of raster angles and layer
thickness on the tensile strength of FDM printed ABS. Three raster angles are
considered, 0◦ , 45◦ and 90◦ and across the range of variables considered samples
printed with a 0◦ raster angle demonstrated the highest tensile strength.
An investigation by [19] utilises slightly different terminology, but also con-
355 siders the effect of raster angle on the strength of specimens printed to the
ASTM D638 standard. Within this standard a range of specimen sizes are
considered and this investigations reviews the results from ‘hourglass’ Type I,
IV and V specimens. In this work ‘longitudinal’ refers to a raster angle of 0◦ ,
‘cross-hatched’ refers to a raster angle alternating by 90◦ between subsequent
360 print layers i.e. 0◦ /90◦ , and ‘transversal’ refers to a raster angle of 90◦ relative
to the length of the specimen. For the two larger specimens investigated, Type
I and IV, a raster angle of 0◦ produced samples with the highest UTS, however
for the smaller sample Type V, a raster angle of 0◦ /90◦ produced the highest
UTS.
365 Raster angle, build direction and material are investigated by [6] who com-
pare both ABS and PC using ASTM D638. Two different raster angles are
considered for the ABS samples: ±45◦ and 0◦ /90◦ . This study finds very little
difference between the UTS of the samples with different raster angels. A raster
angle of 0◦ /90◦ resulted in a UTS 3.7% and 3.0% higher than the ±45◦ for

14
370 samples printed in a flat and upright orientation respectively. In the on-edge
printing orientation 0◦ /90◦ samples were 2.3% weaker. These small differences
between sample strengths are insignificant, particularly when considering con-
fidence intervals of the data.
The final study to be discussed here by [14] was introduced in Section 4.1 and
375 utilises a ‘RepRap’ type printer to investigate the effect of raster angle on ABS
utilising the ASTM D638 standard. Two raster angles are considered: 0◦ /90◦
and ±45◦ . The results demonstrate very little variation in tensile strength
between the two types of sample investigated, although the strongest samples
were printed with a 0◦ /90◦ raster angle.
380 Due to the large number of studies discussed here, a summary of the results
regarding selection of raster angle when printing in ABS is detailed in Table 2.
This section has summarised the results from investigations looking at ABS
and the next two sections will summarise findings from alternative materials.

4.2.2. Raster angle for PLA

385 Fewer studies have looked into the effect of raster angle on the tensile
strength of PLA specimens. [13] investigate the effect of 3 different raster angles
utilising ASTM D638. Raster angels of 0◦ , 90◦ and 45◦ are investigated and
a raster angle of 45◦ is found to produce the strongest specimens, on average
10% stronger than the 0◦ printed specimens. The study also considers fatigue
390 performance of the specimens and concludes 45◦ and 0◦ have the best fatigue
performance, with 45◦ performing better at lower stress levels and 0◦ performing
better at higher stress levels.
A further study is conducted by [18] who also consider both tensile strength
and fatigue performance. This study utilises different terminology, considering
395 printing along the X-direction, the Y-direction and at an angle of 45◦ . Given the
print head for the particular printer technology utilised always moves parallel
to the X-direction, the print direction of the printed part can be considered
a proxy for variation in the raster angle; 0◦ , 90◦ and 45◦ respectively. This
study finds that those samples utilising a raster angle of 0◦ are nearly 25%
400 stronger than those printed at an angle of 90◦ , with samples printed at an angle
of 45◦ achieving UTS values between these two. Fatigue testing demonstrates
a different order of success, with optimum fatigue performance achieved by
samples with a 45◦ raster followed by 90◦ and finally 0◦ raster angles.
A very different testing approach is adopted by [30] who, instead of printing
405 specimens to particular dimensions, print 100% solid blocks of PLA and sub-
sequently machine the test samples from these blocks. ‘Hour-glass’ tensile test
specimens are machined, but they are not manufactured to meet a particular
tensile test standard in this instance. Three different raster angles are used in
the printing of the original blocks, 0◦ , 90◦ and 45◦ . These FDM printed PLA
410 samples are also compared to conventional injection moulded samples. Two
different strain rates are investigated in this study and at both strain rates, the
samples with rasters at 45◦ achieve the highest UTS. The largest difference was
achieved at the higher strain rate, where the 45◦ specimens were 32.8% stronger
than the 90◦ specimens which were the weakest. In contrast to expectations, at

15
Table 2: Summary of studies investigating the effect of raster angle on ABS printed sample
tensile strength. Table notes: † Many of these studies consider multiple variables and as such
there is not one raster angle that achieves maximum tensile strength across all variables;
the angle reported here results in maximum tensile strength for the majority of variables
investigated. *Denotes studies utilising ‘RepRap’ printer technology.

Author(s) Raster angles Raster angle Notes

investigated for max tensile
strength†
Ahn et al. 2002 0◦ , ±45◦ , 0◦ /90◦ , 0◦ 0◦ approx 2
[31] 90◦ times stronger
than 90◦
Sood et al. 2010 0◦ , 30◦ , 60◦ 60◦ Many other
[22] variables investi-
gated
Ziemian et al. 0◦ , 45◦ , 90◦ , 0◦ Second strongest
2012 [34] ±45◦ ±45◦ at 75%
strength of 0◦
Durgan et al. 0◦ , 30◦ , 45◦ , 0◦ 0◦ best when
2014 [25] 60◦ , 90◦ printing flat or
‘on-edge’ only
Rayegani et al. 0◦ , 45◦ 50◦ 50◦ calculated by
2014 [39] applying a DE
algorithm to test
data
Rezayat et al. 0◦ , 45◦ , 90◦ 0◦ Full numeri-
2015 [16] cal data not
provided
Rankouhi et al. 0◦ , 45◦ , 90◦ 0◦ Many variables
2016 [5] investigated
Torrado et al. 0◦ , 0◦ /90◦ , 90◦ 0◦ 0◦ optimal for
2016 [19] larger specimens
I and IV. 0◦ /90◦
optimal for
smaller specimen
V.
Cantrell et al. ±45◦ , 0◦ /90◦ n/a No significant
2017 [6] difference ob-
served.
Tymrak et al. 0◦ /90◦ , ±45◦ 0◦ /90◦ 0◦ /90◦ showed a
2014 [14]* small advantage
over ±45◦

16
 Table 3: Summary of studies investigating the effect of raster angle on PLA printed sample
tensile strength. Table notes: † Some of these studies consider multiple variables and as such
there is not one raster angle that achieves maximum tensile strength across all variables;
the angle reported here results in maximum tensile strength for the majority of variables
investigated. *Denotes studies utilising ‘RepRap’ printer technology.

Author(s) Raster angles Raster angle Notes

investigated for max tensile
strength†
Letcher et al. 0◦ , 90◦ , 45◦ 45◦ 45◦ on average
2014 [13] 10% stronger
than 0◦ .
Afrose et al. 0◦ , 90◦ , 45◦ 0◦ 0◦ approx 25%
2016 [18] stronger than
90◦ .
Song et al. 2017 0◦ , 90◦ , 45◦ , 45◦ Printed in
[30] blocks, then
shaped.
Tymrak et al. 0◦ /90◦ , ±45◦ 0◦ /90◦ Not a large
2014 [14]* improvement
but 0◦ /90◦
marginally
stronger.

415 the higher strain rate, the 45◦ and 0◦ specimens were 24.2% and 11.0% stronger
than the injection moulded specimens respectively. At the lower strain rate
investigated, all three raster angle directions produced samples with strength
exceeding the UTS of the injection moulded samples.
Finally, the study introduced in Section 4.1 by [14] also investigated the
420 relative strength of PLA samples printed using a ‘RepRap’ printer. Again, two
angles were studied: 0◦ /90◦ and ±45◦ . Minimal variation in tensile strength was
observed between these two defined raster angles, though the highest samples
were achieved with a 0◦ /90◦ raster angle.
A summary of the investigations and results for raster angle selection in PLA
425 is detailed in Table 3.

4.2.3. Alternative materials

The majority of the published literature regarding FDM printing focuses
on the common materials utilised in industry: ABS and PLA. An additional
material is investigated in a study by [4] who consider samples printed in poly-
430 carbonate (PC) utilising the ASTM D638 standard. This study uses a different
notation to previous studies addressed and unlike Figure 8 the angles are defined
where 90◦ is a sample with rasters aligned along the length of the loading path.
For clarity in reporting, these results will be converted to the same notation
as the other studies considered. This study gradually alters the raster angle in
435 15◦ increments, and clearly demonstrates that the closer the raster angle is to

17
 Figure 9: Variation in ultimate tensile strength with print raster angle for polycarbonate
(PC) samples tested to the ASTM D638 standard. Average UTS of 6 specimens for each
raster angle detailed. These results are replicated from [4] and revised to align with the raster
nomenclature adopted in this paper. UTS has been converted from PSI to MPa.

alignment with the direction of the tensile load applied, the higher the UTS.
For samples with fully aligned raster angles (0◦ in the other studies we have
considered) the UTS is approximately 3 times the strength of samples where
the load is applied perpendicular to the raster (90◦ ). Figure 9 details the aver-
440 age results from this study, revised to reflect the angle notation adopted in this
review paper.
PC is further considered in a study by [6] which was introduced in Section
4.2.1. Four different raster angles are considered which differ from those in-
vestigated in other studies: ±45◦ , +30◦ / − 60◦ , +15◦ / − 75◦ and 0◦ /90◦ . The
445 study also investigates the effect of print orientation, which affects the optimal
raster orientation selected. For samples printed flat on the printer bed (as de-
tailed in Figure 10) raster angles of ±45◦ and +15◦ / − 75◦ have similar tensile
strength properties and produce significantly stronger samples than the other
angles investigated. For the other print orientations, on-edge and upright, only
450 two raster angles are investigated, ±45◦ and 0◦ /90◦ . Very little difference is
observed between the two raster angles, with a raster angle of ±45◦ producing
samples with very marginally higher UTS.
Further to this [29] consider the effect of raster angle on the tensile strength
of PEEK samples considering 0◦ /90◦ , 30◦ /-60◦ and ±45◦ . The 0◦ /90◦ sam-
455 ples were significantly stronger than the other samples, demonstrating tensile
strength 35.4% and 30.7% higher than 30◦ /-60◦ and ±45◦ respectively.
A summary of the investigations and results for raster angle selection in
alternative materials is detailed in Table 4.
Having considered the effect of raster angle on the tensile strength of FDM
460 printed materials, the next section will consider the effect of print orientation.

18
 Table 4: Summary of studies investigating the effect of raster angle on polycarbonate (PC)
and polyether-ether-ketone (PEEK) printed sample tensile strength. Table notes: † Some of
these studies consider multiple variables and as such there is not one raster angle that achieves
maximum tensile strength across all variables; the angle reported here results in maximum
tensile strength for the majority of variables investigated.

Author(s) Material and Raster angle Notes

raster angles for max tensile
investigated strength†
Hill et al. 2014 PC: 0◦ 0◦ is 3 times
[4] 0◦ - 90◦ in 15◦ in- stronger than
crements 90◦ .
Cantrell et al. PC: ±45◦ and Optimal results
2017 [6] ±45◦ , 0◦ /90◦ , +15◦ / − 75◦ for flat orien-
+30 / − 60◦ ,
◦
tation samples
+15◦ / − 75◦ only.
Wu et al. 2015 PEEK: 0◦ /90◦ 0◦ /90◦ is 35.4%
[29] 0◦ /90◦ , ±45◦ stronger than
◦ ◦
30 / − 60 , 30◦ / − 60◦ .

4.3. Print orientation

When printing a component, the choice of printing orientation relative to the
printer build platform can be selected so that the sample is printed flat, on-edge,
or upright. A good diagram is produced by [20] which clearly describes these
465 print orientations, and is replicated in Figure 10. The choice of build orientation
can affect the mechanical properties of the samples, and this is investigated by
the studies reported below.
For ABS samples print orientation is investigated by [25], who consider flat
printing, on-edge printing and upright printing as identified in Figure 10 (the
470 terminology used in this particular paper are horizontal, vertical and perpen-
dicular respectively). Across a range of raster angles investigated, this study
concludes that flat and on-edge printing produce significantly stronger samples
than upright, typically achieving strengths 50% - 100% higher than samples
printed in the upright direction. There is minimal variation in strength between
475 the flat and on-edge printed specimens; on the whole the flat specimens were
stronger, although the individual sample maximum strength was achieved with
an on-edge print and a 0◦ raster angle. Reasons for this variation in strength
will be discussed in Section 5.3.
A similar study is repeated by [6] who also consider the same three print
480 directions across a range of raster angles for both ABS and PC samples. Con-
sidering the ABS samples, very little variation in UTS is observed between any
of the orientations investigated.
The PC samples investigated by [6] show much more sensitivity to printing
orientation, with those printed on-edge showing the highest tensile strength,
485 closely followed by the flat print orientation. The upright printed samples are

19
 Figure 10: The different build orientation options available for FDM printed samples as
published by [20].

significantly weaker. The strongest sample printed in PC is achieved with an

on-edge printing direction and a raster angle of ±45◦ ; this shows an average
UTS 29.8% stronger than an upright specimen with ±45◦ raster angle.
Finally, printing direction is considered for PLA samples by [20] who also
490 consider the three printing orientations described above in addition to varying
layer thickness. This study finds that flat and on-edge printed samples have
comparable tensile strength performance, with both being significantly stronger
than upright samples. In many cases these samples exhibit twice the UTS of
upright printed samples.
495 A summary of the studies and results investigating the effect of print orien-
tation across a range of materials is detailed in Table 5.

4.4. Layer height

Layer height is a further printing parameter that can be selected during the
printing process and it controls the height of each printed layer. Although not as
500 thoroughly investigated as the previous topics, the following studies investigate
the impact of layer height on the tensile strength of FDM printed samples.
The multi-variate study conducted by [22] into FDM printed ABS samples
considers the effect of printing layer height on sample tensile strength. Three
layer heights are considered: 0.127mm, 0.178mm and 0.254mm. The findings are
505 not explicit in the report, however, the response surfaces published in this paper
appear to show the highest UTS is achieved utilising the thickest layer height
across the range of variables investigated. Potential reasons for this behaviour
are discussed in Section 5.4.
The effect of layer height on ABS parts is further considered by [5] who
510 consider two layers heights, 0.2mm and 0.4mm. This study also varies the total

20
Table 5: Summary of studies investigating the effect of print orientation on printed sample
tensile strength of ABS, PC and PLA. Table notes: † Some of these studies consider multiple
variables and as such the print orientation reported here results in maximum tensile strength
for the majority of variables investigated.

Author(s) Material and Print Notes

print orientation for
orientation max tensile
investigated strength†
Durgun et al. ABS: Flat, on- Flat and on edge Minimal diff’
2014 [25] edge, upright between flat and
on edge. Typ-
ically 50-100%
stronger than
up-right.
Cantrell et al. ABS: Flat, on- None Minimal diff’ ob-
2017 [6] edge, upright served between
any orientations.
Cantrell et al. PC: Flat, on- On-edge Flat also per-
2017 [6] edge, upright formed well but
upright much
weaker.
Chacon et al. PLA: Flat, on- Flat and on-edge Minimal diff’
2017 [20] edge, upright between flat
and on-edge.
Often twice
the strength of
upright.

21
 thickness of the samples tested from 0.2mm to 7mm. Across the full range
of sample thicknesses investigated, 0.2mm printed layers consistently result in
higher sample UTS. This appears to contradict the findings presented above by
[22] and reasons for this will be addressed in the Discussion section 5.4.
515 As previously discussed [14] utilise ‘RepRap’ type printers to investigate the
tensile strength of both ABS and PLA printed samples. This study also consid-
ered the effect of varying three layer heights: 0.4mm, 0.3mm and 0.2mm. For
the ABS samples, layer height made minimal difference; samples printed with
the lowest height, 0.2mm, demonstrated marginally higher UTS. In the PLA
520 samples however, layer height made a more significant difference; on average
samples adopting a 0.2mm layer height had 24.5% and 10.0% greater UTS than
samples printed with a 0.3mm and 0.4mm layer height respectively.
The effect of layer height on the UTS of PLA samples is also investigated
by [20] who consider 4 layer heights: 0.06mm, 0.12mm, 0.18mm, 0.24mm. This
525 study also investigates print orientation (as discussed in Section 4.3) and fila-
ment feed rate (which will be discussed in Section 4.6). In the upright build
orientation, which has significantly lower UTS than on-edge or flat build orien-
tations, a larger layer height increases the UTS across all feed rates investigated.
For the on-edge and flat print directions, an increase in layer height has lim-
530 ited affect on UTS at the lowest feed rate (20mm/s) but at the higher feed
rates (50mm/s and 80mm/s) an increase in layer height is observed to reduce
the UTS. The strongest samples were printed in the flat orientation with the
thinnest layer height, 0.06mm. Reasons for these observed behaviours will be
further discussed in Section 5.4.
535 Given the number of studies investigating the effect of layer height on tensile
strength, a summary of the results is detailed in Table 6.

4.5. Air gap and raster width

Some printing parameters can have a similar effect on the printed specimens
and this is certainly true of air gap and raster width. During printing the defined
540 air gap is the space left between the rasters (or roads) of deposited material,
and the raster width is the specified width of the deposited raster, as detailed
in Figure 11. These two variables can be optimised together to ensure overlap
or a gap between adjacent rasters.
The air gap between rasters is considered by [16] who also investigate the
545 effect of a range of variables on the tensile strength of ABS samples. Three
air gaps are considered in this work -0.05mm, 0.0mm and 0.05mm. Across the
range of raster angles investigated, increasing the air gap consistently reduces
the UTS of the sample, with an air gap of -0.05mm always achieving the highest
strength for any given raster angle. A change in air gap has a more significant
550 impact on samples printed with a raster angle of 45◦ and 90◦ than it does to
samples with a raster angle of 0◦ . This will be discussed in Section 5.5. The
maximum sample UTS is obtained with an air gap of -0.05mm and a raster
angle of 0◦ .
A study by [39] considers the effect of both air gap and raster width on
555 ABS printed samples. Two different air gaps are considered, -0.00254mm and

22
Table 6: Summary of studies investigating the effect of layer height on printed sample tensile
strength of ABS and PLA. Table notes: † Some of these studies consider multiple variables and
as such the layer height reported here results in maximum tensile strength for the majority of
variables investigated. *Represents studies utilising ‘RepRap’ printer technology.

Author(s) Layer Layer Notes

thicknesses thickness for
investigated max tensile
strength†
Sood et al. 2010 ABS: 0.127mm, Variable - not Paper suggests
[22] 0.178mm, clear thinner layers
0.254mm can initially add
strength but also
increase sample
distortion.
Rankouhi et al. ABS: 0.2mm, 0.2mm 0.2mm layer is
2016 [5] 0.4mm strongest across
all raster angles
considered.
Tymrak et al. PLA: 0.4mm, 0.2mm 0.2mm layer is
2014 [14]* 0.3mm, 0.2mm significantly
stronger.
Tymrak et al. ABS: 0.4mm, 0.2mm 0.2mm layer is
2014 [14]* 0.3mm, 0.2mm only marginally
stronger.
Chacon et al. PLA: 0.06mm, 0.06mm Variable results
2017 [20] 0.12mm, depending on
0.18mm, print direction
0.24mm and feed rate.
Strongest sam-
ples use 0.06mm.

(a) Plan view (b) Cross-section

Figure 11: Air gap and raster width definitions for FDM printing. (a) Details a plan view of
the raster pattern showing a positive air gap between adjacent rasters. (b) Details the effect
of air gap selection on the cross-section through adjacent deposited rasters.

23
 (a) Grid (b) Lines (c) Triangles (d) Tetrahedral

(e) Cubic (f) Concentric (g) Concentric 3D (h) Zig Zag

Figure 12: Range of infill options available with Ultimaker replicated from [40].

0.5588mm, and two different raster widths, 0.2034mm and 0.5588mm. Other
variables are also considered in this study but consistently the negative air gap
resulted in a higher sample UTS for all combinations of the other variables.
For a negative air gap, an increase in raster width slightly reduces the UTS of
560 the samples across the range of variables tested. Conversely, for a positive air
gap a higher raster width increases the relative UTS of the samples, although
it should be noted that overall the samples are much weaker than the samples
with a negative air gap. Reasons for this will be addressed in Section 5.5.

4.6. Other variables

565 There are numerous printing variables that can be altered during FDM print-
ing, and those investigated most commonly have been discussed in the sections
above. There are some variables that have not been widely investigated but can
still have an effect on the tensile strength of printed samples and these will be
detailed below.
570 Although the majority of studies addressed above have adopted a 100% infill
for the printed samples, in practice, many practitioners will save money, time
and materials by printing the outline of a shape and infilling it at a reduced
infill density. In addition to specifying the infill density, there are numerous
infill patterns available and this will clearly effect the strength of a sample.
575 Figure 12 outlines the various infill options with a leading printer manufacturer,
Ultimaker [40].
A full investigation of the pros and cons of all these options has not been con-
ducted but a study by [26] investigates the yield strength and specific strength
of both ABS and PLA when printed to either a 100% infill structure, utilising a

24
580 45◦ raster angle, or a honeycomb infill structure made from multiple hexagonal
prisms. The infill density selected for the honeycomb structure is unfortunately
not specified in the paper, although printers commonly default to 20% infill.
This study also investigates a range of different printer outputs; here those
samples printed on a Felix 1.0e will be discussed for consistency. For samples
585 printed in ABS the 100% infill samples had over twice the yield strength of
the honeycomb structure, and the PLA samples had around 2.5 times the yield
strength. This is not a surprising result but the values for specific strength
(σS ), calculated by Equation 1 are perhaps more informative. Here σT = ten-
sile strength and ρ = material density.
σT
Specif ic strength, σS = ( ) (1)
ρ
590 In ABS, the specific strength of the 100% infill samples were approximately
1.4 times the strength of the honeycomb structure, and the 100% PLA samples
were approximately 1.3 times the specific strength of the honeycomb structure.
It is clear that the 100% infill has a measurably higher specific strength.
Another potential variable of the FDM printing process is the feed rate of
595 the print filament; a higher feed rate will clearly speed up the printing process,
leading to quicker production times and lower costs. [20] consider the effect
of this on the tensile strength of samples, investigating the impact of three
feed rates: 20mm/s, 50mm/s and 80mm/s. The study also considers print
orientation and layer height. In the upright build orientation, an increase in
600 feed rate results in a measurable drop in tensile strength of the samples across
all layer heights. For the flat and on-edge samples, feed rate appears to have
minimal impact on the tensile strength of the samples.
In addition to investigating the impact of PLA colour on the tensile strength
of samples as discussed in Section 4.1, [38] also consider the effect of varying the
605 extruder temperature when using ‘RepRap’ type printers. Four printing tem-
peratures are investigated: 190◦ C, 200◦ C, 210◦ C and 215◦ C. A large variation
is apparent in the results but a general correlation of increasing yield strength
with increasing extruder temperature is observed, however there is a slight dip
in sample yield strength at a temperature of 200◦ C. Reasons for this observed
610 behaviour will be discussed in Section 5.6.

5. Discussion
5.1. Material selection
Overall, the studies considering the effect of material selection on tensile
strength find that PLA, PC and PEEK all out-perform ABS. Various reasons
615 are discussed for this. In addition to higher tensile strength, [6] suggest that PC
samples showed much lower coefficients of variation (COV), a measure of relative
variability, than the ABS samples. The study points out that the printer used
for manufacturing the PC samples was a professional grade printer, compared
to the ‘hobby-grade’ printer used for the ABS samples; this could have affected
620 variability and quality of the produced samples.

25
 The study by [14] utilise a range of ‘Rep-rap’ printers of a similar grade
to compare ABS and PLA and demonstrate that PLA has a higher tensile
strength. The failure surfaces of these samples are assessed and it is found
that PLA specimens demonstrate superior inter-raster and inter-layer bonding,
625 appearing more like a “homogeneous solid than a composition of individual
extruded rasters”. This superior bonding will lead to improved tensile strength
performance. This is further supported by the claim in this study that ‘Rep-Rap’
printed PLA samples can achieve comparable strength to injection moulded
PLA parts (which are a homogeneous solid, without inter-raster or inter-layer
630 bonds). ‘Rep-Rap’ ABS parts however, are generally weaker than injection
moulded alternatives. The fact that ‘Rep-Rap’ printed PLA parts can achieve
tensile strengths equivalent to injection moulded parts demonstrates the quality
of the inter-raster and inter-layer bonding in parts printed with this material.
The study also suggests there is significant variety in filament characteristics
635 even for the same material classification and argues filament vendors should
provide better data including composition and mechanical test data for the
printing filament itself.
It is also suggested by [29] that inter-raster and inter-layer bonding may
be the cause of different tensile strength results. In this study SEM (Scanning
640 Electron Microscope) imaging is used to review fracture surfaces and again finds
that in ABS samples the individual rasters can be clearly seen. However, in the
stronger PEEK samples, the fracture surface appears to be one homogeneous
block. Given the relatively new introduction of PEEK this study suggests that,
in time, the printing parameters with this material can be further optimised
645 leading to an even greater tensile strength improvement over ABS.
The investigation by [15] that considers including additives to create an ABS
composite also utilises SEM to interpret the observed results. For those sam-
ples loaded with jute fibre and printed in the flat plane, the fractured samples
were shown to have “multiple craters and voids”, which would clearly lead to a
650 reduction in tensile strength. This is believed to be due to the decomposition
of the jute fibre at 180◦ C, well below the extrusion temperature used in the
printing process. This process of decomposition leads to by-products and gases
creating the observed voids. ABS samples incorporating TiO2 were shown to
have the highest tensile strength and the study suggests the presence of TiO2
655 limits the ability of the plastic macromolecules to slide over one another, which
can be seen by the brittle fracture surface observed in the samples. Brenken
et al. [8] also cite void formation, in addition to fibre damage during printing,
as reasons for under-performing fibre reinforced composites. This review also
highlights the importance of sufficient wetting of the composite fibres during
660 the printing process to maximise the strength of continuous fibre composites.
Further demonstrating the variation within material classifications [38] show
a significant variation between PLA samples printed with different colour fila-
ments; natural PLA, with no added dye, has the highest tensile strength. X-ray
powder diffraction (XRD) is utilised to understand the reasons for this variation.
665 It is found that the variation in tensile strength is related to the crystallinity of
the printed parts, which is dependent on filament colour; the specimens printed

26
 using natural PLA have the lowest % crystallinity when analysed utilising XRD.

5.2. Raster orientation

There is a majority consensus amongst the studies considering ABS that
670 the highest tensile strength is achieved with a 0◦ raster angle. This is due to
the alignment of the tensile loading along the length of the raster (trans-raster
strength) as opposed to across inter-raster bonds. [34] however does warn that,
whilst achieving the highest tensile strength, samples printed with a 0◦ raster
angle are more susceptible to variations in the strength of the mono-filament
675 feedstock than samples printed with alternative raster directions.
Interestingly, [19] look at the relative strength of a range of different sized
hour-glass ABS specimens, printed with consistent printing parameters. This
work demonstrates that the dimensions of the specimen can affect what optimum
printing parameters are required to achieve maximum UTS.
680 Although a variety of results are reported by [22], the highest tensile strength
in the ABS samples is obtained with a raster angle of 60◦ . This higher raster
angle results in shorter raster lengths in the samples and the paper suggests
these shorter raster lengths reduce distortion in the samples, increasing their
strength. Conversely, the paper also suggests that lower raster angles (e.g. 0◦ )
685 result in tensile loading along the length of the raster which should improve
strength, as suggested by many of the other publications.
Fewer studies are conducted looking at the effect of raster angle on PLA
samples and there is reduced consensus with alteration to raster angle appear-
ing to have less impact on sample tensile strength. This could be due to the
690 improved inter-raster and inter-layer bonding achieved with PLA as discussed in
Section 5.1. Interestingly [13] review the quality of the printed samples and ob-
serve that for the 0◦ samples a gap is apparent between the ‘shell’ and the main
body of the specimen due to the construction of the raster roads. Gaps such
as this will certainly weaken the structure, leading to lower tensile strength. In
695 some cases, this gap led to the outer shell separating from the main body of the
sample during tensile testing. This gap however, is not apparent in the 45◦ and
90◦ samples. This finding suggests the 0◦ raster angle is less well suited to the
specific geometry of the tensile test samples but may not necessarily produce
weaker products overall.
700 A further PLA study by [18] finds that 0◦ raster angle has the highest UTS
followed by 45◦ then 90◦ . In agreement with many of the ABS studies, this paper
cites the alignment of the tensile load along the raster roads as the predominant
reason for the superior tensile performance with 0◦ rasters. This theory is also
supported by [29], who demonstrate superior strength in PEEK printed with a
705 0◦ raster angle, and [4], who make the same conclusion for PC samples.

5.3. Print orientation

Although there is some variation in the results, most of the studies agree that
samples printed in the upright orientation perform significantly worse in tensile
testing than those printed flat or on-edge. [25] suggests that the noticeable

27
710 weakness in the upright samples occurs due to the predominant load being
carried across the printed layers rather than along the length of the rasters;
the links between adjacent layers are referred to as inter-layer fusion bonds by
[20]. This inter-layer bonding between consecutive layers is much weaker than
the trans-raster strength along the length of the rasters, and hence samples
715 printed in the upright direction prove to be significantly weaker. This theory is
supported by [20] who suggest the difference in UTS due to print orientation is
attributable to the increased number of the weaker, inter-layer fusion bonds in
the upright samples.
Interestingly, [6] observe very little variation in tensile strength with print
720 orientation in ABS but significant variation with PC samples. This demon-
strates that print orientation needs to be optimised for the selected printing
material (as the strength of the inter-layer and inter-raster bonds will be strongly
affected by printing material as well as print parameters).
Print direction will also effect printing times and hence production costs.
725 This is addressed by [25] and [20] where the data shows both flat and on-edge
samples printed to ASTM D638 dimensions are significantly quicker to print
than upright samples (although print time is also affected by layer height). The
consideration of print time provides further confirmation that upright printing
should be avoided.
730 It is clear from most of the studies that FDM printed samples demonstrate
significant anisotropy and some further studies have looked at techniques for re-
ducing this behaviour. For example, [41] utilise ionizing radiation with copoly-
mer blends to improve the mechanical performance of PLA. Through exposure
to gamma rays post printing, inter-layer adhesion of the samples was improved
735 via the introduction of crosslinks between polymer chains. This study demon-
strates this technique can be used to improve the tensile strength of FDM sam-
ples and reduce anisotropy. Another study by [37] also seeks to reduce the
anisotropy of FDM printed samples by enhancing ABS with additives. Six
polymer matrix and four polymer blends are investigated, and although it is
740 shown that anisotropy can be reduced, this comes at the expense of an overall
reduction in the UTS of the samples.
Further studies of this nature have the potential to both reduce anisotropy
and improve the mechanical performance of FDM printed samples, and are an
area of continued research.

745 5.4. Layer height

The effect of layer height on ABS printed samples is investigated by [22] who,
in contrast to other papers find that a thicker layer height results in higher tensile
strength. The authors discuss a range of reasons for the observed variations.
A greater number of layers can result in a high temperature gradient at the
750 base of the part which can improve strength by increasing the diffusion between
adjacent rasters but it can also decrease strength as the temperature gradient
can lead to sample distortion. They also suggest a higher number of layers
increases the number of heating and cooling cycles the sample is subject to,
which can result in the accumulation of residual stress within the sample. The

28
755 authors therefore suggest that increasing the individual layer height reduces the
total number of layers required, which, due to the above reasons, increases the
strength of the sample.
The opposite effect is observed in a study by [5], who also consider ABS.
Here, the lower layer height results in higher sample UTS. To understand this be-
760 haviour, this study investigates the printed sample structures by using a Keyence
VHX-600 digital microscope to quantify the air-gap to material ratio for sam-
ples printed with differing layer heights. The sample printed with a greater layer
height, 0.4mm, had a 5.26% air-gap to material ratio compared to the 0.2mm
layer sample, which had a 0.3% ratio. This reduced air-gap to material ratio for
765 the samples with lower layer height results in more material to carry the tensile
load and hence a higher UTS.
These results are further supported by [20] who find that for PLA sam-
ples printed in a flat or on-edge orientation a lower layer height results in a
higher tensile strength. For samples printed in an upright orientation however,
770 the lower layer height reduces the tensile strength. This is due to the previ-
ously discussed issue of inter-layer fusion between consecutive layers resulting
in weaker links than trans-raster loading. In an upright sample, a reduction
in layer height actually increases the number of weak inter-layer fusion bonds
across which the tensile force is experienced, resulting in a reduction in overall
775 tensile strength.
As discussed in Section 5.3, layer height will also affect printing time and
therefore production costs. It is shown by [20] that the lower the layer height,
the longer the printing time; reducing layer height from 0.24mm to 0.06mm
can increase the print time by up to 300%. Despite the fact that reducing
780 layer height can improve product mechanical properties, this must be balanced
against the associated increase in print time and production costs. The optimal
solution will therefore be very project and product dependant.

5.5. Air gap and raster width

The effect of varying the air gap and the sensitivity of this depending on
785 raster angle selection is highlighted by [16] who find that a slightly negative
air gap produces samples with the highest UTS. The negative air gap creates
better boding between adjacent raster roads and hence improves the UTS of
the samples at all raster angles. The effect of increasing the air gap has an
increasingly negative impact on 45◦ and 90◦ raster angles because, due to the
790 tensile loading direction, the tensile strength of these samples is more reliant on
inter-raster bonding. Increasing the air gap in this instance reduces the strength
of the inter-raster bonding and hence reduces the overall UTS of the samples.
In samples with a 0◦ raster angle the loading is predominantly trans-raster so
although increasing the air gap does reduce the strength of the samples, the
795 effect is not as severe as for samples with 45◦ and 90◦ raster angles.
The pattern of a higher observed UTS with smallest air gap is also observed
in a study by [39] who find that a negative air gap consistently results in a
higher sample UTS across a range of variables tested in ABS samples. As
described above, the negative air gap essentially leads to better bonding between

29
800 consecutive raster roads in a given layer and there is more material to carry the
tensile load for a given unit area; hence the UTS goes up. This paper also
considers the effect of raster width, and demonstrates that optimum tensile
strength is achieved when correctly selecting raster width and air gap to be
complementary, achieving optimum bonding between consecutive raster roads.
805 This paper does warn about ‘overfill’ flaws in samples occurring when a negative
air gap is used with a thicker raster width, essentially resulting in a 12.5%
overlap between raster roads. This ‘overfill’ can create flaws and an unpleasant
surface appearance and is shown to slightly reduce the UTS of the samples
investigated. The correct balance between air gap and raster width must be
810 achieved to ensure minimal air gap and good bonding between consecutive raster
roads without excessive material leading to instances of ‘overfill’.

5.6. Other variables

The effect of the infill pattern is investigated by [26] who consider a 100%
infill density in comparison to a honeycomb structure. This study finds that the
815 specific strength of the honeycomb structure is measurably less than that of the
filled structure. The study concludes that despite making a more lightweight
structure that will be quicker to print, the loss in strength when utilising an
infill pattern should be considered.
Filament feed rate is found to have minimal impact on the tensile strength
820 of PLA samples printed in the flat and on-edge orientations within the bounds
tested (20-80 mm/s) by [20]. A higher feed rate can be selected in these instances
to speed up the printing process. However, for samples printed in the upright
direction, a higher speed rate can reduce the tensile strength of the samples and
should be avoided. This could be due to the increased number of inter-layer
825 bonds in the upright samples which may be weaker with a higher feed rate.
A general trend of increasing sample yield strength with extruder tempera-
ture is observed by [38] when using a ‘RepRap’ printer to print PLA samples.
The study also considers the effect of extruder temperature on the crystalline
structure of samples utilising XRD. The lowest % crystallinity was observed for
830 the samples printed at 200◦ C and this also corresponds with the lowest yield
strength of all the samples. This trend does not follow throughout the other
results however, as crystallinity peaks at 210◦ C and then significantly drops off
but tensile strength continues to increase. The study also suggests that a higher
printing temperature may allow better inter-layer bonding to occur before the
835 printing materials cool to the glass transition temperature. This improved inter-
layer bonding will result in higher yield strengths.

5.7. Overall discussion

The benefit of altering various printing parameters to optimise component
tensile strength is clear to see in the presented results (Section 4). It should be
840 highlighted however, that these studies are based on idealised samples with sim-
ple geometry specifically developed for unidirectional tensile testing purposes.
In reality, printed products will rarely have such simplicity and the loading and

30
 hence stress distribution within them will be much more complex. The results
presented must therefore be interpreted and optimised for any particular ge-
845 ometry. The use of FEA numerical models to identify the stress distribution
and hence allow the user to select the optimum print parameters (such as print
direction and raster angle) for that geometry should be considered.
The majority of the studies considered in this review are empirical studies
presenting results from physical test campaigns. Whilst this satisfies the main
850 objective of this paper, studies addressing the physical processes governing FDM
printing provide further insight into the observed results, and highlight opportu-
nities to use predictive tools and numerical models to predict printed component
properties. This area of study is addressed by [8] who discuss several studies of
interest.
855 For example, the tensile strength of printed components has been shown
to be strongly dependant on the strength of the inter-raster and inter-layer
bonds. Various physical processes govern the formation of these bonds and
are considered in detail by [42, 43, 44, 45], with [16] developing filament and
macro scale FE models to consider the effect or raster angle and air gap in ABS
860 printed parts and comparing results to a physical test campaign. In addition to
this, the heat transfer and solidification of the printed parts will also affect the
tensile strength. Two early papers, [46] and [47], develop 1D and 2D models
respectively of the thermal processes involved in FDM. Further studies have
been conducted to develop the understanding of these processes including [48,
865 49, 50, 51, 52, 53] and [54].
The high temperatures involved in the printing process can also lead to
residual stress accumulation and/or deformation in the produced part. Analytic
solutions for simple geometries have been developed to predict the warpage
of printed components by [48] and [55]. A 3D FEA model of the printing
870 process is developed by [56] and is subsequently used to develop experimental
investigations [57]. 3D simulations of composite printed parts are also presented
by [58] and [59].
Despite this large body of work, investigating and modelling the physical
processes involved in FDM additive manufacturing, the conclusion of the review
875 paper by [8] is that many of the models are overly simplified, and do not fully
describe the processes. It is suggested that future research should seek to develop
further modelling tools to more accurately predict the printing outcomes and
therefore create more certainty on printed product mechanical properties.

6. Conclusions

880 Additive manufacturing is a rapidly developing sector, with continual progress

in printed product quality. With these developments the technology is transi-
tioning from a prototype printing tool to a manufacturing method in its own
right. FDM is one of the most common forms of 3D printing with many hob-
byist as well as professional printers adopting this technology. With numerous
885 printing variables available for each print run, having the knowledge to opti-

31
 mise the printing process to achieve particular material properties is clearly
advantageous.
This paper has reviewed a range of recent publications aiming to optimise
the FDM printing process in order to improve the tensile strength of printed
890 samples. Reviewing the range of methodologies applied by the different stud-
ies highlights the need for specific methodologies for the mechanical testing of
additive manufactured components. This would allow for a more systematic
approach across the sector. Any new methodology should permit test pieces
of greater thickness to allow for investigation into the many internal structures
895 possible with 3D printed products.
Although not all the studies concur on all printing variables, some key recom-
mendations can be made to optimise the tensile strength of samples as detailed
below.

1. Material: On average, PLA is shown to have 1.1 to 2 times the tensile

900 strength of ABS. PC is shown to have 1.9 times the tensile strength of
ABS, and PEEK is shown to have 2.1 times the strength of ABS, with
a high potential for further improvement through printing optimisation.
Additives to standard materials can both improve and reduce the tensile
performance of FDM samples; adding TiO2 to ABS was shown to improve
905 tensile strength. Overall, continuous fibre reinforced composites show the
highest potential for tensile strength improvement. Even the colour of
PLA filament can effect tensile strength, with the strongest samples man-
ufactured from natural PLA with no added dye.
2. Raster angle: Many studies considered the effect of raster angle on ABS
910 samples with the majority concurring that a 0◦ raster angle, where the
predominant load is carried along the length of the raster, resulted in the
highest tensile strength. In some cases this achieved 2 times the tensile
strength of samples with a raster angle of 90◦ . Fewer studies were con-
ducted with PLA, concluding that either 0◦ or 45◦ achieved highest tensile
915 strength, with 90◦ raster angles resulting in weaker samples. PC studies
also varied in conclusion with one study clearly demonstrating a better
tensile performance for 0◦ raster angle and another study demonstrating
marginally better tensile strength performance with ±45◦ raster angle.
3. Print orientation: Generally, printing in the upright orientation should
920 be avoided if tensile strength is a priority. Printing in the flat or on-edge
orientation achieves better tensile performance for ABS, PC and PLA, of-
ten achieving twice the tensile strength of up-right printed samples. Mini-
mal variation is observed between the strength of flat and on-edge printed
samples.
925 4. Air gap/raster width: Air gap and raster width should be optimised
together, to ensure high quality inter-raster bonding without ‘overfill’.
Consideration should be given to selecting a negative air gap to achieve
this.

32
 5. Layer height: For flat and on-edge orientations, layer height should be
930 minimised in order to achieve maximum tensile strength. This improves
the strength for both ABS and PLA samples considered, with one PLA
study demonstrating a 24.5% tensile strength improvement when reducing
layer height from 0.4mm to 0.2mm. Reduced layer height increases print
time, so the improvement in tensile strength should be balanced against
935 the increased manufacturing time (which leads to increased product costs).
6. Other variables: The following variables have been considered in this
paper but need more investigation.
(a) Infill: Numerous infill options are available, and the choice of infill
should be selected to balance print time and print materials against
940 the achieved product tensile strength. Clearly 100% infill will result
in higher tensile strength, and one study demonstrated that it also
showed highest specific strength. Further work is required on the
numerous options available to optimise infill patterns and to strike
the desired balance between printing time and materials used Vs.
945 product tensile strength.
(b) Printing temperature: Although, only considered in one study, an in-
crease in extruder temperature was shown to improve tensile strength
performance due to improved inter-raster and inter-layer bonding.
Further research on this topic is required.
950 (c) Feed rate: The feed rate of the printing filament is considered in one
study and is found to have limited effect on flat or on-edge samples
though some effect is observed in upright samples. The feed rate
should therefore be optimised to minimise printing time, rather than
optimise material properties.

955 In summary, there are numerous printing parameters available when utilising
AM technology. The conclusions presented in this paper can act as a robust
and pragmatic reference point for users seeking to optimise their FDM printing
processes regarding product tensile strength.
Research and development of new materials, different post processing tech-
960 niques and alternative printing parameters will continue in this fast moving
technology field. The development of numerical modelling packages to improve
the prediction of material properties for these products is required, and is a
key challenge for the sector given the fast pace of technology development. Un-
doubtedly, the mechanical properties of FDM printed components will continue
965 to improve, making the use of this technology as a large scale production tech-
nique increasingly plausible.

7. Acknowledgements

This work was funded through the European Union under the European Re-
gional Development Funding (ERDF) Marinei, Grant/Award Number: 05R16P00381.

33
 970 The work was commissioned by 3D Kernow in order to optimise their printing
processes to better serve the additive manufacturing requirements of the marine
sector in the Cornwall and Isles of Scilly region.

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