Enhancing Mechanical Properties of 3d-Printed Pla Composites Via Topology Optimization and Nickel Coating

Abstract

Polylactic acid (PLA) is widely used in additive manufacturing due to its biodegradability and ease of processing. However, its mechanical limitations restrict its applicability in structural components. This study pioneers a unique integration of topology optimization and electrolytic nickel coating for PLA composites, marking a significant advancement in lightweight and high-strength material development. PLA specimens were fabricated using the fused deposition modeling (FDM) technique and subsequently coated with nickel at thicknesses of 5 mu m and 10 mu m via electrolytic deposition after surface activation with conductive graphite spray. Three-point bending tests were performed to evaluate the effects of topology optimization and nickel coating on mechanical properties. Experimental results demonstrated that topology optimization led to a weight reduction of up to 45%, while nickel coating significantly improved mechanical performance. The flexural strength of PLA increased by 60%, from 45 MPa (uncoated) to 72 MPa (10 mu m nickel-coated), while Young's modulus improved by 125%, making it comparable to conventional structural polymers. Nickel-coated samples demonstrated significant improvements in flexural strength and modulus, along with enhanced resistance to environmental degradation, indicating superior durability for long-term applications. These findings highlight the potential of PLA-based hybrid materials as viable alternatives to lightweight metal alloys in applications requiring both strength and corrosion resistance, such as aerospace components, automotive structures, and medical implants.