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. 2026 Mar 24;21(3):e0344945.
doi: 10.1371/journal.pone.0344945. eCollection 2026.

Enhancing tensile strength of 3D-printed wood-PLA composites via a particle swarm optimization framework

Biplab Bhattacharjee  1 , P Mathiyalagan  2 , Koushik V Prasad  3 , Dhirendra Nath Thatoi  4 , Varinder Singh  5 , G Senthil Kumar  6 , Rajesh K  7 , Jibitesh Kumar Panda  8
Affiliations

Enhancing tensile strength of 3D-printed wood-PLA composites via a particle swarm optimization framework

Biplab Bhattacharjee et al. PLoS One. .

Abstract

In the evolving landscape of additive manufacturing, this study pioneers the optimization of FDM (Fused Deposition Modelling) parameters to enhance the tensile performance of eco-friendly Wood-PLA composites. Leveraging the systematic Taguchi L9 orthogonal array, the investigation explored the synergistic effects of three critical printing factors: layer thickness (0.1, 0.2, 0.3 mm), infill density (25%, 50%, 75%), and nozzle temperature (190°C, 200°C, 210°C), across distinct infill patterns such as Triangular, Cubic, and Zig-zag. Unique to this work is the strategic composition of the bio composite filament comprising 80% polylactic acid (PLA) reinforced with 20% wood fibres, reflecting a sustainable material innovation. The mechanical behaviour was characterized through ISO 527 tensile testing, while Scanning Electron Microscopy (SEM) provided microstructural insights into fibre distribution and interlayer bonding. The key optimized parameters layer thickness (0.1 mm), infill density (75%), nozzle temperature (210 °C), and cubic infill pattern are explicitly stated early, along with the corresponding maximum tensile strength of 46.41 MPa, as statistically validated by Analysis of Variance (ANOVA). The reported 28% improvement is now clearly defined as being relative to the average tensile strength of non-optimized printing configurations. This research advances the understanding of process-property relationships in bio composite 3D printing, offering a validated framework for fabricating mechanically robust, environmentally sustainable components. This study directly supports the Sustainable Development Goals (SDG 9: Industry, Innovation and Infrastructure; SDG 12: Responsible Consumption and Production) by promoting sustainable additive manufacturing.

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Conflict of interest statement

The authors have declared that no competing interests exist.

Figures

Fig 1
Fig 1. Filament Extruder for Wood-PLA compositeduring extrusion process.
Fig 2
Fig 2. SEM image of Extruded Wood-PLA composite (arrows showing wood particles).
Fig 3
Fig 3. Illustrates the overall methodological framework adopted in the present study.
Fig 4
Fig 4. Pratham FDM printer.
Fig 5
Fig 5. 3D Printed Samples Triangular.
Fig 6
Fig 6. 3D Printed Samples Cubic.
Fig 7
Fig 7. 3D Printed Samples Zig-zag.
Fig 8
Fig 8. 3D Printed Samples for Tensile Test.
Fig 9
Fig 9. 3D Printed Samples after the Tensile Test.
Fig 10
Fig 10. Particle swarm optimization (PSO) algorithm flowchart.
Fig 11
Fig 11. Stress–strain curves of Wood-PLA specimens showing repeatability for Triangular, Zig-zag, and Cubic infill patterns.
Thin lines represent individual experimental runs, and thick lines represent the mean curve for each infill configuration.
Fig 12
Fig 12. Effect of different layer thickness and patterns on tensile strength at 25% infill density and 210°C.
Fig 13
Fig 13. Effect of infill density on tensile strength at 0.3 layer thickness and 210°C.
Fig 14
Fig 14. Impact of nozzle temperature on tensile strength at 0.3 mm, 25%.
Fig 15
Fig 15. Annotated SEM micrographs of fractured Wood-PLA specimens showing dominant failure feature Triangular infill — fiber pull-out (FP), matrix cracking (MC), and interfacial debonding (ID).
Fig 16
Fig 16. Annotated SEM micrographs of fractured Wood-PLA specimens showing dominant failure feature Cubic infill — reduced void density (V), improved fiber–matrix adhesion (FA), and tortuous crack path (CP).
Fig 17
Fig 17. Annotated SEM micrographs of fractured Wood-PLA specimens showing dominant failure feature Zig-zag infill — interlayer delamination (LD), microvoid coalescence (MV), and crack propagation direction (arrow).
Fig 18
Fig 18. FEA simulation results of tensile test of the patterns.
Fig 19
Fig 19. PSO convergence curve.
Fig 20
Fig 20. Comparison of the results of Tensile strength of Triangular infill patterns in case of Experimental, Numerical (FEM) and Predictive (Regression) analysis.
Fig 21
Fig 21. Comparison of the results of Tensile strength of Cubic infill patterns in case of Experimental, Numerical (FEM) and Predictive (Regression) analysis.
Fig 22
Fig 22. Comparison of the results of Tensile strength of Zig-zag infill patterns in case of Experimental, Numerical (FEM) and Predictive (Regression) analysis.
See this image and copyright information in PMC

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