This study aims to explore the impact of printing parameters, specifically raster angle and layer thickness, on the microstructure and mechanical properties of green and sintered parts produced through filament-based fused filament fabrication (FFF) using a self-developed filament. The goal is to improve the quality and performance of the final sintered components.
A filament containing 92 Wt.% 316L stainless steel with polyoxymethylene (POM)-based binder was formulated and evaluated for flexibility through a buckling resistance test. Green parts were printed with varying raster angles (+45°/−45°, 0°/90°) and layer thicknesses (0.2 mm, 0.3 mm), followed by catalytic debinding and high-temperature sintering. Microstructure, dimensional accuracy and mechanical properties, including microhardness, tensile strength and elongation at break, were analyzed to identify optimal parameters.
A raster angle of (+45°/−45°) produced denser interlayer bonding and a more compact green part structure, whereas a thicker layer (0.3 mm) resulted in a looser structure with larger pores. The optimal combination of +45°/−45° raster angle and 0.2 mm layer thickness achieved the highest relative density (99.37%) and superior mechanical properties: microhardness (216.83 HV), tensile strength (467.59 MPa) and elongation at break (16.81%).
A 92 Wt.% 316L stainless-steel filament for FFF was independently developed and near dense steel components were successfully fabricated. This study provides new insight into developing a novel formula of filament and optimizing printing parameters for FFF technology.
