Influence of single and multi-angle raster patterns on the mechanical performance of fused filament fabricated conductive PLA composites

Abstract

Additive manufacturing, particularly fused filament fabrication (FFF), enables the production of complex, customized polymer composite products with tunable mechanical properties. Electrically conductive polylactic acid (CPLA) composites are increasingly being applied in sensors, flexible electronics, and structural-functional components due to their combined electrical conductivity and mechanical performance. This study examines the influence of raster angle (RA) configurations on the mechanical properties of electrically conductive CPLA composites fabricated via FFF. 30 RA configurations, including unidirectional and periodic paths, were tested for impact strength, Young’s modulus, yield strength, and break strain. Results revealed strong anisotropy, with RA = 0° achieving optimal performance: yield strength of 31.87 MPa, modulus of 780.2 MPa, break strain of 8.41 %, and impact strength of 114.49 kJ/m ² . Composite desirability analysis confirmed RA = 0° (index 0.873) as optimal, balancing stiffness, strengths, and ductility. RA = 15° yielded the highest impact resistance (127.49 kJ/m ² ) but lower strength and strain. Periodic RAs such as (0, 45, 90, −45) and (0, 15, …, 165) enhanced ductility but reduced strength, suiting deformation-tolerant applications. These findings provide a practical framework for tailoring the mechanical performance of conductive polymer composites through RA optimization, supporting their effective potential deployment in advanced engineering and multifunctional applications.