Additive manufacturing (AM) methods are increasingly being adopted as an alternative for mass production. In particular, Fused Deposition Modeling (FDM) technology is leading the way in this field. However, the adhesion of the layers in products produced using FDM technology is an important issue. These products are particularly vulnerable to forces acting parallel to the layers and especially to impact strength. Most products used in the industry have complex geometries and thin walls. Therefore, solid infill is often required in production, and this production must take place in the ZX orientation. This study aims to optimize the impact strength against loads acting parallel to the layers (ZX orientation) of PA6, one of the most widely used materials in the industry. This orientation is critical in terms of mechanical properties, and the mechanical characteristics are significantly lower compared to other orientations. In this study, filaments containing pure PA6 with 15% short carbon fiber and 30% glass fiber were utilized. Additionally, the printing temperature, layer thickness and heat treatment duration were used as independent variables. An L9 orthogonal array was employed for experimental design and then each experiment was repeated three times to conduct impact strength tests. Characterization, Taguchi optimization, and factor analyses were performed, followed by fracture surface characterization by SEM. As a result, the highest impact strength was achieved with pure PA6 at 8.9 kJ/m², followed by PA6 GF30 at 8.1 kJ/m², and the lowest impact strength was obtained with PA6 CF15 at 6.258 kJ/m². Compared to the literature and manufacturer datasheets, it was concluded that the impact strength values had significantly increased and the chosen experimental factors and their levels, particularly nozzle temperature, were effective.

The additive manufacturing sector is rapidly developing, providing alternatives for mass production in the polymer composite industry. Due to the direction-dependent mechanical properties and high cost of fiber-reinforced polymeric materials, it is necessary to take advantage of alternative multi-materials and production technologies. In this study, a special geometric-shaped knitting technique was investigated using two different materials. The main material was polyamide 6 (PA6), and the inner or second material was PA6 with a 30 wt.% glass fiber addition by weight (PA6GF30). The special geometric shape, layer thickness, nozzle temperature, and post-heat treatment time were measured as process parameters in the production of the PA6/PA6GF30 composites with the fused deposition modeling (FDM) technique. The Taguchi design method and L9 fractional experiment were used in the experimental study. The mechanical behaviors of the PA6/PA6GF30 samples were obtained using tensile and impact tests. In addition, scanning electron microscopy (SEM) analyses were performed on the fracture lines of the PA6/PA6GF30 samples, and damage analyses were carried out in more detail. The experimental results were sorted using grey relational analysis (GRA). Moreover, the optimal experimental conditions and their related plots were obtained. As a result, the highest tensile strength of the PA6GF30 composite was 89.89 MPa with the addition of a special geometric shape. In addition, the maximum impact resistance value of the PA6/PA6GF30 composite was 83 kJ/m². Hence, the developed knitting method presented many advantages when using the FDM technique, and both were successfully used to produce the PA6/PA6GF30 composites.