Enhancing Mechanical Properties of Ultrasonically-Treated 3D-Printed Acrylonitrile- Butadiene-Styrene and Polylactic Acid Parts: A Full Factorial Design Approach

This study explores the enhancement of mechanical properties in 3D-printed polylactic acid and acrylonitrile-butadiene-styrene parts through ultrasonic treatment. Tensile samples were fabricated using fused filament fabrication with varying infill percentages (60% and 100%) and layer thicknesses (0.15 mm and 0.30 mm). Post-processing involved a high-power ultrasonic treatment for 2 seconds, followed by tensile testing. The results demonstrated an average 10% increase in tensile strength for both acrylonitrile-butadiene-styrene and polylactic acid after ultrasonic treatment, with the highest tensile strengths measured at approximately 41 MPa and 38 MPa, respectively. However, strain at fracture experienced a decline, except in the samples with an infill percentage of 100 and a number of layers of 10. Scanning electron microscopy revealed dimensional changes and raster merging, more pronounced in 60% and 100% infill samples, respectively. The study employed a comprehensive full factorial design of experiments and finite element simulation for ultrasonic treatment setup design. The interaction of 3D printing and ultrasonic treatment parameters was investigated, with the infill percentage exhibiting the most substantial impact on the ultimate tensile strength. The results highlight the potential of ultrasonic treatment to enhance mechanical properties, reduce defects, and improve the structural integrity of 3D-printed components.