Evaluation of a Novel Method for Fused Deposition Modeling Wall Construction

Abstract

Fused Deposition Modeling (FDM) is a popular additive manufacturing method; however, its anisotropic mechanical properties, notably reduced strength in the Z-direction, remain a major challenge. This study explores a novel, software-driven dual-offset wall slicing technique designed to enhance the density and tensile strength of FDM parts without altering hardware or materials. Specimens composed oof polylactic acid (PLA) and acrylonitrile butadiene styrene (ABS) were printed using standard slicing methods and two offset approaches: horizontal and vertical wall staggering. The samples were produced in multiple thicknesses and build orientations, then tested through density measurements, microscopic cross-sectional analysis, and tensile testing according to ASTM D638-22 standards. Contrary to expectations, the offset techniques did not improve mechanical performance. Although vertical offsets increased part density, both offset methods resulted in decreased tensile strength across all orientations, with vertical offsets nearly halving strength in some cases. Cross-sectional images showed poor interlayer contact in thin deposition lines and altered porosity distributions that disrupted load paths. Analysis indicates that the proposed slicing strategies require optimized processing parameters, such as adjusted line widths and flow rates, to be effective. The results demonstrate the potential of wall-staggering techniques but also highlight the need for further refinement to achieve strength improvements in FDM-printed parts.