ArticleMaterials (Basel, Switzerland)2026
Experimental Study on the Influence of Inter-Layer Ironing Parameters on the Surface Quality of MEX-Fabricated PLA-LW and PLA Parts.
Article in Materials (Basel, Switzerland), 2026. The graph could read no effect estimate from its abstract, so it casts no vote on the map. Not yet cited in PubMed.
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Abstract
The current trend in both academic research and industrial applications is to expand the use of additive manufacturing processes across an increasing number of functional domains. This has led to substantial efforts aimed at improving the overall performance of additively manufactured components, particularly those produced by Material Extrusion (MEX). One of the main limitations of MEX-fabricated parts is the presence of air voids formed between deposited lines and layers, which reduce mechanical strength and structural uniformity. In this context, the present study investigates the influence of inter-layer ironing process parameters, an approach intended to modify near-surface morphology and improve the surface quality and dimensional accuracy of two commonly used materials, namely lightweight polylactic acid (PLA-LW) and standard. The experimental setup involved varying the ironing direction, nozzle diameter, and ironing spacing, while keeping all other manufacturing parameters constant. A complete 4 × 3 × 3 factorial experimental design was employed, considering three process parameters: ironing direction at four levels, nozzle diameter at three levels, and ironing spacing at three levels, resulting in 36 parameter combinations applied to each material separately. Performance evaluation included surface roughness (S
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