A Comparative Applied Study on Optimizing Printing Parameters for Six Fused Deposition Modeling Materials

The characteristics of six materials [acrylonitrile butadiene styrene (ABS), polylactic acid (PLA), thermoplastic polyurethane (TPU), polyvinyl alcohol (PVA), polyethylene terephthalate glycol (PETG), and polycarbonate (PC)] were tested in 3D-printed trimalleolar fracture models and compared under different conditions. A corresponding L9 (3(4)) orthogonal array was applied to optimize the printing parameters. The printing time, weight, cost, surface roughness, height, support removal time, mechanical properties, and sterilization of models printed with the six materials were recorded. Both doctors and patients evaluated the models. ABS models had the shortest printing time, lightest weight, lowest cost, shortest time of removal support structure and best accuracy. PLA models soon fractured during loading compression force. TPU models had the heaviest weight and longest time of removal support structure, least compression force, largest deformation. PVA models had the longest printing time and highest cost. PETG models were the least accurate. PC models can load more compression strength. PLA and TPU maintained shape after sterilization; however, ABS, PVA, PC, and PETG deformed during sterilization. Patients preferred the PLA and 1:1 scale model, whereas doctors preferred the TPU and 80% scale models. Based on orthogonal experiments, printing parameters were comprehensively balanced to provide an important basis for printing models with different purposes in orthopedics.