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INVESTIGATION OF THE EFFECTS OF PROCESS PARAMETERS ON MACHINING PERFORMANCE IN LASER CUTTING OF 3D-PRINTED PLA

Yıl 2025, Cilt: 9 Sayı: 1, 9 - 20, 30.04.2025

Oğuzhan Der , Gökhan Başar

https://doi.org/10.46519/ij3dptdi.1581618

Öz

In the current research, the influences of process parameters on surface roughness and kerf width in CO₂ laser cutting of PLA plates produced by the fused filament fabrication method were experimentally investigated. Laser cutting was performed using three plate thicknesses (2, 3, and 4 mm), three cutting speeds (3, 6, and 9 mm/s), and three laser power levels (90, 95, and 100 W). Surface roughness was determined with a surface roughness tester, and kerf widths were evaluated using a digital microscope. The findings indicate that higher cutting speeds and lower laser power lead to a reduction in both surface roughness and kerf width. Higher cutting speeds combined with lower laser power decreased the thermal effect during cutting by reducing the interaction between the laser and material, resulting in lower surface roughness and narrower kerf width. The effect of plate thickness on surface roughness and kerf width was complex, varying with cutting speed and laser power. The lowest surface roughness (0.951 µm) and kerf width (0.793 mm) values were achieved with a plate thickness of 3 mm, a cutting speed of 9 mm/s, and a laser power of 90 W. This study provides valuable insights into how laser cutting parameters affect the surface quality and dimensional accuracy of PLA plates, contributing to quality improvements in industrial applications. The results highlight the essential influence of cutting speed and laser power on managing surface roughness and kerf width, thus aiding in optimizing the process.

Anahtar Kelimeler

Laser cutting Fused filament fabrication PLA Surface roughness Kerf width.

Kaynakça

  • 1. Altan, M., Eryildiz, M., Gumus, B., Kahraman, Y., “Effects of process parameters on the quality of PLA products fabricated by fused deposition modeling (FDM): Surface roughness and tensile strength”, Materials Testing, Vol. 60, Issue 5, Pages 471-477, 2018.
  • 2. Mushtaq, R.T., Iqbal, A., Wang, Y., Khan, A.M., Petra, M.I., “Advancing PLA 3D printing with laser polishing: Improving mechanical strength, sustainability, and surface quality”, Crystals, Vol. 13, Issue 4, 626, 2023.
  • 3. Eryildiz, M., “Comparison of notch fabrication methods on the impact strength of FDM-3D-printed PLA specimens”, Materials Testing, Vol. 65, Issue 3, Pages 423–430, 2023.
  • 4. Alabd, M.U., Temiz, A., “Optimization of annealing and 3D printing process parameters of PLA parts”, International Journal of 3D Printing Technologies and Digital Industry, Vol. 8, Issue 2, Pages 185-201, 2024.
  • 5. Arslan, O., Selvi, O., Totuk, O.H., “Characterization of 3D printed conductive flexible materials for soft robotic applications”, International Journal of 3D Printing Technologies and Digital Industry, Vol. 8, Issue 1, Pages 1-7, 2024.
  • 6. Kechagias, J.D., Vidakis, N., Petousis, M., Mountakis, N., “A multi-parametric process evaluation of the mechanical response of PLA in FFF 3D printing”, Materials and Manufacturing Processes, Vol. 38, Issue 8, Pages 941-953, 2023.
  • 7. Der, O., Marengo, M., Bertola, V., “A low cost, flexible pulsating heat pipe technology”, Proceeding of 3rd Thermal and Fluids Engineering Conference (TFEC), Pages 321–327, Fort Lauderdale, 2018.
  • 8. Der, O., Edwardson, S., Marengo, M., Bertola, V., “Engineered composite polymer sheets with enhanced thermal conductivity”, IOP Conference Series: Materials Science and Engineering, Vol. 613, Issue 1, 012008, 2019.
  • 9. Davim, J.P., Oliveira, C., Barricas, N., Conceição, M., “Evaluation of cutting quality of PMMA using CO2 lasers”, The International Journal of Advanced Manufacturing Technology, Vol. 35, Issues 9-10, Pages 875-879, 2008.
  • 10. Fountas, N. A., Ninikas, K., Chaidas, D., Kechagias, J., Vaxevanidis, N.M., “Neural networks for predicting kerf characteristics of CO2 laser-machined FFF PLA/WF plates”, MATEC Web of Conferences, Vol. 368, 01010, 2022. 11. Kechagias, J.D., Ninikas, K., Petousis, M., Vidakis, N., Vaxevanidis, N., “An investigation of surface quality characteristics of 3D printed PLA plates cut by CO2 laser using experimental design”, Materials and Manufacturing Processes, Vol. 36, Issue 13, Pages 1544-1553, 2021.
  • 12. Moradi, M., Karami Moghadam, M., Shamsborhan, M., Bodaghi, M., Falavandi, H., “Post-processing of FDM 3D-printed polylactic acid parts by laser beam cutting”, Polymers, Vol. 12, Issue 3, 550, 2020.
  • 13. Kechagias, J.D., Fountas, N.A., Ninikas, K., Vaxevanidis, N.M., “Kerf geometry and surface roughness optimization in CO2 laser processing of FFF plates utilizing neural networks and genetic algorithms approaches”, Journal of Manufacturing and Materials Processing, Vol. 7, Issue 2, 77, 2023.
  • 14. Tsiolikas, A., Kechagias, J.D., Zaoutsos, S.P., “Hybrid fuzzy logic approach for multi-objective optimisation in laser-based processes”, International Journal of Mechatronics and Manufacturing Systems, Vol. 17, Issue 1, Pages 1-20, 2024.
  • 15. Kechagias, J.D., Ninikas, K., Salonitis, K., “An experimental study of laser cutting of PLA-wood flour 3D printed plates using a modified Taguchi design”, International Journal of Experimental Design and Process Optimisation, Vol. 7, Issue 1, Pages 62-75, 2022.
  • 16. Petousis, M., Ninikas, K., Vidakis, N., Mountakis, N., Kechagias, J.D., “Multifunctional PLA/CNTs nanocomposites hybrid 3D printing integrating material extrusion and CO2 laser cutting”, Journal of Manufacturing Processes, Vol. 86, Pages 237-252, 2023.
  • 17. Kechagias, J.D., Vidakis, N., Ninikas, K., Petousis, M., Vaxevanidis, N.M., “Hybrid 3D printing of multifunctional polylactic acid/carbon black nanocomposites made with material extrusion and post-processed with CO2 laser cutting”, The International Journal of Advanced Manufacturing Technology, Vol. 124, Pages 1843-1861, 2023.
  • 18. Kechagias, J.D., Ninikas, K., Petousis, M., Vidakis, N., “Laser cutting of 3D printed acrylonitrile butadiene styrene plates for dimensional and surface roughness optimization”, The International Journal of Advanced Manufacturing Technology, Vol. 119, Pages 2301-2315, 2022.
  • 19. Sabri, H., Mehrabi, O., Khoran, M., Moradi, M., “Leveraging CO2 laser cutting for enhancing fused deposition modeling (FDM) 3D printed PETG parts through postprocessing”, Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering, 2024.

INVESTIGATION OF THE EFFECTS OF PROCESS PARAMETERS ON MACHINING PERFORMANCE IN LASER CUTTING OF 3D-PRINTED PLA

Yıl 2025, Cilt: 9 Sayı: 1, 9 - 20, 30.04.2025

Oğuzhan Der , Gökhan Başar

https://doi.org/10.46519/ij3dptdi.1581618

Öz

In the current research, the influences of process parameters on surface roughness and kerf width in CO₂ laser cutting of PLA plates produced by the fused filament fabrication method were experimentally investigated. Laser cutting was performed using three plate thicknesses (2, 3, and 4 mm), three cutting speeds (3, 6, and 9 mm/s), and three laser power levels (90, 95, and 100 W). Surface roughness was determined with a surface roughness tester, and kerf widths were evaluated using a digital microscope. The findings indicate that higher cutting speeds and lower laser power lead to a reduction in both surface roughness and kerf width. Higher cutting speeds combined with lower laser power decreased the thermal effect during cutting by reducing the interaction between the laser and material, resulting in lower surface roughness and narrower kerf width. The effect of plate thickness on surface roughness and kerf width was complex, varying with cutting speed and laser power. The lowest surface roughness (0.951 µm) and kerf width (0.793 mm) values were achieved with a plate thickness of 3 mm, a cutting speed of 9 mm/s, and a laser power of 90 W. This study provides valuable insights into how laser cutting parameters affect the surface quality and dimensional accuracy of PLA plates, contributing to quality improvements in industrial applications. The results highlight the essential influence of cutting speed and laser power on managing surface roughness and kerf width, thus aiding in optimizing the process.

Anahtar Kelimeler

Laser cutting Fused filament fabrication PLA Surface roughness Kerf width.

Kaynakça

  • 1. Altan, M., Eryildiz, M., Gumus, B., Kahraman, Y., “Effects of process parameters on the quality of PLA products fabricated by fused deposition modeling (FDM): Surface roughness and tensile strength”, Materials Testing, Vol. 60, Issue 5, Pages 471-477, 2018.
  • 2. Mushtaq, R.T., Iqbal, A., Wang, Y., Khan, A.M., Petra, M.I., “Advancing PLA 3D printing with laser polishing: Improving mechanical strength, sustainability, and surface quality”, Crystals, Vol. 13, Issue 4, 626, 2023.
  • 3. Eryildiz, M., “Comparison of notch fabrication methods on the impact strength of FDM-3D-printed PLA specimens”, Materials Testing, Vol. 65, Issue 3, Pages 423–430, 2023.
  • 4. Alabd, M.U., Temiz, A., “Optimization of annealing and 3D printing process parameters of PLA parts”, International Journal of 3D Printing Technologies and Digital Industry, Vol. 8, Issue 2, Pages 185-201, 2024.
  • 5. Arslan, O., Selvi, O., Totuk, O.H., “Characterization of 3D printed conductive flexible materials for soft robotic applications”, International Journal of 3D Printing Technologies and Digital Industry, Vol. 8, Issue 1, Pages 1-7, 2024.
  • 6. Kechagias, J.D., Vidakis, N., Petousis, M., Mountakis, N., “A multi-parametric process evaluation of the mechanical response of PLA in FFF 3D printing”, Materials and Manufacturing Processes, Vol. 38, Issue 8, Pages 941-953, 2023.
  • 7. Der, O., Marengo, M., Bertola, V., “A low cost, flexible pulsating heat pipe technology”, Proceeding of 3rd Thermal and Fluids Engineering Conference (TFEC), Pages 321–327, Fort Lauderdale, 2018.
  • 8. Der, O., Edwardson, S., Marengo, M., Bertola, V., “Engineered composite polymer sheets with enhanced thermal conductivity”, IOP Conference Series: Materials Science and Engineering, Vol. 613, Issue 1, 012008, 2019.
  • 9. Davim, J.P., Oliveira, C., Barricas, N., Conceição, M., “Evaluation of cutting quality of PMMA using CO2 lasers”, The International Journal of Advanced Manufacturing Technology, Vol. 35, Issues 9-10, Pages 875-879, 2008.
  • 10. Fountas, N. A., Ninikas, K., Chaidas, D., Kechagias, J., Vaxevanidis, N.M., “Neural networks for predicting kerf characteristics of CO2 laser-machined FFF PLA/WF plates”, MATEC Web of Conferences, Vol. 368, 01010, 2022. 11. Kechagias, J.D., Ninikas, K., Petousis, M., Vidakis, N., Vaxevanidis, N., “An investigation of surface quality characteristics of 3D printed PLA plates cut by CO2 laser using experimental design”, Materials and Manufacturing Processes, Vol. 36, Issue 13, Pages 1544-1553, 2021.
  • 12. Moradi, M., Karami Moghadam, M., Shamsborhan, M., Bodaghi, M., Falavandi, H., “Post-processing of FDM 3D-printed polylactic acid parts by laser beam cutting”, Polymers, Vol. 12, Issue 3, 550, 2020.
  • 13. Kechagias, J.D., Fountas, N.A., Ninikas, K., Vaxevanidis, N.M., “Kerf geometry and surface roughness optimization in CO2 laser processing of FFF plates utilizing neural networks and genetic algorithms approaches”, Journal of Manufacturing and Materials Processing, Vol. 7, Issue 2, 77, 2023.
  • 14. Tsiolikas, A., Kechagias, J.D., Zaoutsos, S.P., “Hybrid fuzzy logic approach for multi-objective optimisation in laser-based processes”, International Journal of Mechatronics and Manufacturing Systems, Vol. 17, Issue 1, Pages 1-20, 2024.
  • 15. Kechagias, J.D., Ninikas, K., Salonitis, K., “An experimental study of laser cutting of PLA-wood flour 3D printed plates using a modified Taguchi design”, International Journal of Experimental Design and Process Optimisation, Vol. 7, Issue 1, Pages 62-75, 2022.
  • 16. Petousis, M., Ninikas, K., Vidakis, N., Mountakis, N., Kechagias, J.D., “Multifunctional PLA/CNTs nanocomposites hybrid 3D printing integrating material extrusion and CO2 laser cutting”, Journal of Manufacturing Processes, Vol. 86, Pages 237-252, 2023.
  • 17. Kechagias, J.D., Vidakis, N., Ninikas, K., Petousis, M., Vaxevanidis, N.M., “Hybrid 3D printing of multifunctional polylactic acid/carbon black nanocomposites made with material extrusion and post-processed with CO2 laser cutting”, The International Journal of Advanced Manufacturing Technology, Vol. 124, Pages 1843-1861, 2023.
  • 18. Kechagias, J.D., Ninikas, K., Petousis, M., Vidakis, N., “Laser cutting of 3D printed acrylonitrile butadiene styrene plates for dimensional and surface roughness optimization”, The International Journal of Advanced Manufacturing Technology, Vol. 119, Pages 2301-2315, 2022.
  • 19. Sabri, H., Mehrabi, O., Khoran, M., Moradi, M., “Leveraging CO2 laser cutting for enhancing fused deposition modeling (FDM) 3D printed PETG parts through postprocessing”, Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering, 2024.
Toplam 18 adet kaynakça vardır.

Ayrıntılar

Birincil Dil İngilizce
Konular Makine Mühendisliğinde Optimizasyon Teknikleri
Bölüm Araştırma Makalesi
Yazarlar

Oğuzhan Der 0000-0001-5679-2594

Gökhan Başar 0000-0002-9696-7579

Yayımlanma Tarihi 30 Nisan 2025
Gönderilme Tarihi 8 Kasım 2024
Kabul Tarihi 6 Ocak 2025
Yayımlandığı Sayı Yıl 2025 Cilt: 9 Sayı: 1

Kaynak Göster

APA Der, O., & Başar, G. (2025). INVESTIGATION OF THE EFFECTS OF PROCESS PARAMETERS ON MACHINING PERFORMANCE IN LASER CUTTING OF 3D-PRINTED PLA. International Journal of 3D Printing Technologies and Digital Industry, 9(1), 9-20. https://doi.org/10.46519/ij3dptdi.1581618
AMA Der O, Başar G. INVESTIGATION OF THE EFFECTS OF PROCESS PARAMETERS ON MACHINING PERFORMANCE IN LASER CUTTING OF 3D-PRINTED PLA. IJ3DPTDI. Nisan 2025;9(1):9-20. doi:10.46519/ij3dptdi.1581618
Chicago Der, Oğuzhan, ve Gökhan Başar. “INVESTIGATION OF THE EFFECTS OF PROCESS PARAMETERS ON MACHINING PERFORMANCE IN LASER CUTTING OF 3D-PRINTED PLA”. International Journal of 3D Printing Technologies and Digital Industry 9, sy. 1 (Nisan 2025): 9-20. https://doi.org/10.46519/ij3dptdi.1581618.
EndNote Der O, Başar G (01 Nisan 2025) INVESTIGATION OF THE EFFECTS OF PROCESS PARAMETERS ON MACHINING PERFORMANCE IN LASER CUTTING OF 3D-PRINTED PLA. International Journal of 3D Printing Technologies and Digital Industry 9 1 9–20.
IEEE O. Der ve G. Başar, “INVESTIGATION OF THE EFFECTS OF PROCESS PARAMETERS ON MACHINING PERFORMANCE IN LASER CUTTING OF 3D-PRINTED PLA”, IJ3DPTDI, c. 9, sy. 1, ss. 9–20, 2025, doi: 10.46519/ij3dptdi.1581618.
ISNAD Der, Oğuzhan - Başar, Gökhan. “INVESTIGATION OF THE EFFECTS OF PROCESS PARAMETERS ON MACHINING PERFORMANCE IN LASER CUTTING OF 3D-PRINTED PLA”. International Journal of 3D Printing Technologies and Digital Industry 9/1 (Nisan 2025), 9-20. https://doi.org/10.46519/ij3dptdi.1581618.
JAMA Der O, Başar G. INVESTIGATION OF THE EFFECTS OF PROCESS PARAMETERS ON MACHINING PERFORMANCE IN LASER CUTTING OF 3D-PRINTED PLA. IJ3DPTDI. 2025;9:9–20.
MLA Der, Oğuzhan ve Gökhan Başar. “INVESTIGATION OF THE EFFECTS OF PROCESS PARAMETERS ON MACHINING PERFORMANCE IN LASER CUTTING OF 3D-PRINTED PLA”. International Journal of 3D Printing Technologies and Digital Industry, c. 9, sy. 1, 2025, ss. 9-20, doi:10.46519/ij3dptdi.1581618.
Vancouver Der O, Başar G. INVESTIGATION OF THE EFFECTS OF PROCESS PARAMETERS ON MACHINING PERFORMANCE IN LASER CUTTING OF 3D-PRINTED PLA. IJ3DPTDI. 2025;9(1):9-20.
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