Error introduced by direct 3D printing of compression samples of PLA made by FDM process

This study delves into the crucial aspect of sample preparation methodology and its profound impact on characterizing the physical and mechanical properties of components fabricated through the material extrusion (fused deposition modeling—FDM) process. Two distinct manufacturing approaches, direct printing and sample extraction from a plate, were employed to produce samples. To assess the influence of artifacts introduced by direct printing, compression tests were conducted under various loading directions. The investigation extends to density measurements and comprehensive morphological analysis, which plays a pivotal role in understanding the ramifications of different manufacturing approaches and principal sample directions. Notably, the research findings reveal that direct printing inflicts significant artifacts within the samples, fundamentally altering the properties obtained during testing. These artifacts substantially affect density measurements and mechanical behavior, indicating a potential avenue for future research and applications. Besides, the printing direction also significantly influenced the extent of the artifacts and differences in mechanical behavior. The maximum difference in density measurement was − 5.3%, while Young’s modulus reached − 29%, and yield strength ranged between − 12% (for vertical samples) and + 18% for horizontal samples with filaments arranged along the loading path. These findings underscore the necessity for meticulously crafted quality assessment protocols when utilizing functional parts manufactured through the material extrusion process. Such protocols should also consider the influence of sample dimensions on the mechanical characteristics of the components.