Enhancing tensile strength of 3D-printed wood-PLA composites via a particle swarm optimization framework

Biplab Bhattacharjee, P Mathiyalagan, Koushik V Prasad, Dhirendra Nath Thatoi, Varinder Singh, G Senthil Kumar, Rajesh K. and Jibitesh Kumar Panda

PLOS ONE, 2026, vol. 21, issue 3, 1-29

Abstract: In the evolving landscape of additive manufacturing, this study pioneers the optimization of FDM (Fused Deposition Modelling) parameters to enhance the tensile performance of eco-friendly Wood-PLA composites. Leveraging the systematic Taguchi L9 orthogonal array, the investigation explored the synergistic effects of three critical printing factors: layer thickness (0.1, 0.2, 0.3 mm), infill density (25%, 50%, 75%), and nozzle temperature (190°C, 200°C, 210°C), across distinct infill patterns such as Triangular, Cubic, and Zig-zag. Unique to this work is the strategic composition of the bio composite filament comprising 80% polylactic acid (PLA) reinforced with 20% wood fibres, reflecting a sustainable material innovation. The mechanical behaviour was characterized through ISO 527 tensile testing, while Scanning Electron Microscopy (SEM) provided microstructural insights into fibre distribution and interlayer bonding. The key optimized parameters layer thickness (0.1 mm), infill density (75%), nozzle temperature (210 °C), and cubic infill pattern are explicitly stated early, along with the corresponding maximum tensile strength of 46.41 MPa, as statistically validated by Analysis of Variance (ANOVA). The reported 28% improvement is now clearly defined as being relative to the average tensile strength of non-optimized printing configurations. This research advances the understanding of process-property relationships in bio composite 3D printing, offering a validated framework for fabricating mechanically robust, environmentally sustainable components. This study directly supports the Sustainable Development Goals (SDG 9: Industry, Innovation and Infrastructure; SDG 12: Responsible Consumption and Production) by promoting sustainable additive manufacturing.

Date: 2026
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Persistent link: https://EconPapers.repec.org/RePEc:plo:pone00:0344945

DOI: 10.1371/journal.pone.0344945

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