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This paper aims to understand the effect of extrusion conditions on the degree of foaming of polylactic acid (PLA) during three-dimensional (3D) printing. It was also targeted to optimize the slicing parameters for 3D printing and to study how the properties of printed parts are influenced by the extrusion conditions.

This study used a commercially available PLA filament that undergoes chemical foaming. An extrusion 3D printer was used to produce individual extrudates and print samples that were characterized using an optical microscope, scanning electron microscope and custom in-house apparatuses.

The degree of foaming of the extrudates was found to strongly depend on the extrusion temperature and the material feed speed. Higher temperatures significantly increased the number of nucleation sites for the blowing agent as well as the growth rate of micropores. Also, as the material feed speed increased, the micropores were allowed to grow bigger which resulted in higher degrees of foaming. It was also found that, as the degree of foaming increased, the porous parts printed with optimized slicing parameters were lightweight and thermally less conductive.

This study fills the gap in literature where it examines the foaming behavior of individual extrudates as they are extruded. By doing so, this work distinguishes the effect of extrusion conditions from the effect of slicing parameters on the foaming behavior which enhances the understanding of extrusion of chemically foamed PLA.