3D printing offers a significant advantage in the production of hollow parts through the use of infill patterns. However, these patterns are typically generated by slicer software with a primary focus on providing basic structural rigidity, while neglecting other important criteria. This paper presents a simplified infill scaling technique for fused deposition modeling (FDM) and evaluates its effectiveness through tensile tests. The research question addressed in this study is whether adjusting the size of the pattern can reduce print time while maintaining the same stiffness at a given infill ratio. The methodology involves analyzing the results obtained from the tensile tests. The findings reveal that the print time can be reduced to some extent by properly adjusting the size of the infill pattern. However, it is observed that the mechanical resistance is influenced by the layer formation process. In conclusion, this research contributes to understanding the relationship between infill scaling, print time reduction, and mechanical resistance in FDM 3D printing.

Designing components is a complex task, which depends on the component function, the raw material, and the production technology. In the case of rotating parts with higher RPM, the creep and orientation are essential material properties. The PLA components made with the material extrusion process are more resistant than VeroWhite (material jetting) and behave similarly to weakly cross-linked elastomers. Also, based on the tensile tests, Young’s modulus shows minimal anisotropy. Multilinear isotropic hardening and modified time hardening models are used to create the finite element model. Based on the measurements, the finite element method simulation was identified. The deformation in the compressor wheel during rotation became definable. It was concluded that the strain of the compressor wheel manufactured with material extrusion technology is not significant.

Additive Manufacturing (AM) with the consisting constantly evolving technologies is a particularly popular research area. Based on the shape forming freedom, size, shape, and topology optimization techniques can be validated by AM produced parts. However, in every manufacturing process, AM also has some adverse inherent properties. One and maybe the most significant optimization problem is the mechanical anisotropy caused by the layered structure. In this paper, a simultaneous build orientation and shape optimization method is presented. Both of the approaches are intended to increase the mechanical performance of the produced parts. Shape optimization was accomplished by varying the cross-section of the beam geometries, based on the angle between a PSL section and the characteristic load direction. To test the efficiency and validate the method 2D structures (with relatively small 3rd dimension) and their tensile properties were tested. Based on the results, we can prove that the PSL method works and help to increase the mechanical performance by 19.2% with only 7.8% size increment.

The great advantage of additive manufacturing is the fact that hollowed parts with a given infill can be created. However, the standardized commercial slicer software offers a uniform infill pattern creation solution. In engineering practice, the manufactured parts are functional, therefore the appropriate load bearing capacity is mostly mandatory. In this paper a simplified local infill size optimization method has been presented. Based on a Finite Element Analysis the local density of the pattern can be adjusted, according to the emerged local stresses. The results show that independently of the pattern type, if the scaling was applied, the mechanical resistance was improved to the same extent. In case of the worst-performing uniform pattern, 84% improvement in mechanical resistance was achieved with the optimization. In addition, an FDM printing problem has been highlighted, which must be eliminated if the proposed method is used.

Topology optimization and Generative Design are two methods to create volume or stiffness optimized parts and they are used more frequently nowadays. However, the specific methods are often not well described and the connection between these two is not clearly explained. In this article, a force-flow based topology optimization process has been explained in detail and extended with a function to be able to use as a Generative Design tool. The proposed algorithm has been tested on three 2D shapes and the effectiveness was evaluated. This work clarifies the vague description of theoretical solutions by presenting in detail the operation of the algorithm and bridging the lack of information that exists between the shape or topology optimization procedure and the generative design solution.

In recent years, additive manufacturing, especially 3D printing, has been gaining more space in the production of parts and components in various industries. Among the polymer materials, polylactic acid (PLA) stands out due to its renewable sources, such as corn starch or sugar cane. This study focused on the evaluation of the coefficient of friction (CoF) and wear resistance of pins of pure PLA, pure thermoplastic polyurethane (TPU), and bronze‐filled PLA (BRO), all produced by fused deposition modeling (FDM). The pins were rubbed against a SAE 1020 steel counterpart in a pin‐on‐disc apparatus. The wear tests also included combinations of BRO/PLA and TPU/PLA (with a pattern on the surface), combined at three different percentages (25%, 50%, and 75%). Pure BRO showed the lowest wear rate ( K ≈0.9 × 10 ⁻⁵ mm ³ /N m), while pure PLA exhibited the lowest CoF among the pins ( μ ≈0.24) but the highest wear ( K ≈16.7 × 10 ⁻⁴ mm ³ /N m). The combination of 75% of BRO with 25% of PLA demonstrated a favorable balance between friction and wear, with a wear resistance close to BRO ( K ≈0.8 × 10 ⁻⁵ mm ³ /N m) and a CoF similar to pure PLA ( μ ≈0.28). The paper extensively discusses the wear mechanisms observed on the worn surfaces, as well as the tribofilm formed on the steel disc counterpart.