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Integrated Design and Process Optimization of FDM-Fabricated Hexagonal Architected Thin-Walled PA12 Tubes for Improved Compressive and Energy Absorption Performance
Centre of Excellence in Digital Manufacturing, Department of Mechanical Engineering, Rajalakshmi Engineering College, Chennai, India.ORCID iD: 0000-0001-7331-2476
Centre of Excellence in Digital Manufacturing, Department of Mechanical Engineering, Rajalakshmi Engineering College, Chennai, India.ORCID iD: 0000-0003-3168-4882
Centre for Material Science, Easwari Engineering College, Chennai, India.ORCID iD: 0000-0003-1408-9934
Luleå University of Technology, Department of Civil, Environmental and Natural Resources Engineering, Structural and Fire Engineering.ORCID iD: 0000-0002-5474-1512
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2026 (English)In: Macromolecular materials and engineering, ISSN 1438-7492, E-ISSN 1439-2054, Vol. 311, no 8, article id e70309Article in journal (Refereed) Published
Abstract [en]

Thin-walled structures fabricated via Fused Deposition Modeling (FDM) offer high strength-to-weight ratios and geometrically customisable configurations. This study examined how five hexagonal wall architectures of progressively increasing nodal connectivity (D1–D5), three layer heights (0.1, 0.2, and 0.3 mm), and two print angle orientations (0° and 90°) influence the compressive strength, energy absorption, and dimensional accuracy of nylon PA12 tubes under quasi-static uniaxial compression. A Taguchi L30 mixed orthogonal array was used to structure the 30 experimental runs, whereas signal-to-noise (S/N) analysis ranked parameter influence, and Grey Relational Analysis (GRA) resolved the competing compressive-strength and dimensional-accuracy objectives. The most complex architecture (D5) at 90°/0.1 mm achieved the highest compressive strength (144.75 MPa) and energy absorption (4.23 J), whereas the intermediate architecture (D3) at 0°/0.1 mm gave the lowest length error (0.03 mm). Layer height dominated compressive strength (S/N range 0.826 dB), and architected design governed dimensional accuracy (S/N range 4.162 dB). In the multi-response analysis, run T13 (D3/0°/0.1 mm) attained the highest grey relational grade (GRG = 0.8623), whilst the Taguchi main-effect analysis of GRG identified D5/90°/0.1 mm as the optimal factor-level combination, with layer height exerting the greatest combined influence. 

Place, publisher, year, edition, pages
John Wiley and Sons Inc , 2026. Vol. 311, no 8, article id e70309
Keywords [en]
additive manufacturing, fused deposition modeling, grey relational analysis, thin-walled tube
National Category
Mechanical Engineering
Research subject
Fire Technology
Identifiers
URN: urn:nbn:se:ltu:diva-119383DOI: 10.1002/mame.70309ISI: 001842708300001Scopus ID: 2-s2.0-105046807750OAI: oai:DiVA.org:ltu-119383DiVA, id: diva2:2092708
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Available from: 2026-08-17 Created: 2026-08-17 Last updated: 2026-08-17Bibliographically approved

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Karupaiah, VigneshwaranNarayanan, VenkateshwaranKannan, GokulDas, OisikShanmugam, Vigneshwaran
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