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Enhancing additive manufacturing for multi-layer samples: experimental analysis of aluminum sheet thickness and perforation geometry via fused filament fabrication

Roohi, Amir H.; Sadooghi, Ali; Nourian, Amir; Hashemi, Seyed Jalal; Dashti, Babak; Rahmani, Kaveh

Enhancing additive manufacturing for multi-layer samples: experimental analysis of aluminum sheet thickness and perforation geometry via fused filament fabrication Thumbnail


Authors

Ali Sadooghi

Profile image of Amir Nourian

Dr Amir Nourian A.Nourian@salford.ac.uk
Associate Professor in Mechanical Eng.

Seyed Jalal Hashemi

Babak Dashti

Kaveh Rahmani



Abstract

The widespread integration of 3D printing technologies across diverse sectors, including prototyping and automotive industries, underscores their growing importance. This study aims to investigate the influence of aluminium sheet parameters (specifically, thickness, number, and perforation diameter) on the mechanical properties of multi-layer specimens fabricated using Fused filament fabrication (FFF) 3D printing. Polylactic acid sheets were deposited on both sides of aluminium sheets, creating a sandwich structure to enhance strength and flexibility. Aluminium sheets of varying thickness (1 mm and 2 mm) with perforations of 5 mm and 7 mm diameters were examined. Mechanical testing included flexural, compression, and impact assessments. Results from the flexural tests demonstrated that specimens reinforced with 2 mm thick aluminum sheets exhibited significantly higher force at failure. Compression testing revealed a notable increase in maximum compressive force for samples incorporating aluminium sheets. Charpy impact testing indicated an 882% improvement in impact strength for samples with a 2 mm aluminium sheet compared to those without. These findings highlight the critical role of aluminium sheet parameters in enhancing the mechanical performance of FFF-printed multi-layer structures. The study provides valuable insights for optimizing the design and fabrication of composite materials in additive manufacturing applications. The enhanced mechanical properties observed underscore the potential for these materials in sectors requiring robust and resilient components, such as aerospace and automotive industries.

Journal Article Type Article
Acceptance Date Mar 5, 2025
Online Publication Date Mar 19, 2025
Deposit Date Mar 25, 2025
Publicly Available Date Mar 25, 2025
Journal Discover Applied Sciences
Electronic ISSN 3004-9261
Publisher Springer
Peer Reviewed Peer Reviewed
Volume 7
Issue 4
Pages 236
DOI https://doi.org/10.1007/s42452-025-06690-2
Keywords Additive manufacturing, 3D printing, Multi-layer sheets, PLA, Mechanical properties, Aluminium

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Publisher Licence URL
http://creativecommons.org/licenses/by-nc-nd/4.0/

Copyright Statement
Open Access This article is licensed under a Creative Commons Attribution-NonCommercial-NoDerivatives 4.0 International License, which permits any non-commercial use, sharing, distribution and reproduction in any medium or format, as long as you give appropriate credit to the original author(s) and the source, provide a link to the Creative Commons licence, and indicate if you modified the licensed material. You do not have permission under this licence to share adapted material derived from this article or parts of it. The images or other third party material in this article are included in the article’s Creative Commons licence, unless indicated otherwise in a credit line to the material. If material is not included in the article’s Creative Commons licence and your intended use is not permitted by statutory regulation or exceeds the permitted use, you will need to obtain permission directly from the copyright holder. To view a copy of this licence, visit http://creativecommons.org/licenses/by-nc-nd/4.0/.





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