Effects of printing parameters on the properties of 316L stainless steel fabricated by fused filament fabrication

Purpose This study aims to explore the impact of printing parameters, specifically raster angle and layer thickness, on the microstructure and mechanical properties of green and sintered parts produced through filament-based fused filament fabrication (FFF) using a self-developed filament. The goal is to improve the quality and performance of the final sintered components. Design/methodology/approach A filament containing 92 Wt.% 316L stainless steel with polyoxymethylene (POM)-based binder was formulated and evaluated for flexibility through a buckling resistance test. Green parts were printed with varying raster angles (+45°/−45°, 0°/90°) and layer thicknesses (0.2 mm, 0.3 mm), followed by catalytic debinding and high-temperature sintering. Microstructure, dimensional accuracy and mechanical properties, including microhardness, tensile strength and elongation at break, were analyzed to identify optimal parameters. Findings A raster angle of (+45°/−45°) produced denser interlayer bonding and a more compact green part structure, whereas a thicker layer (0.3 mm) resulted in a looser structure with larger pores. The optimal combination of +45°/−45° raster angle and 0.2 mm layer thickness achieved the highest relative density (99.37%) and superior mechanical properties: microhardness (216.83 HV), tensile strength (467.59 MPa) and elongation at break (16.81%). Originality/value A 92 Wt.% 316L stainless-steel filament for FFF was independently developed and near dense steel components were successfully fabricated. This study provides new insight into developing a novel formula of filament and optimizing printing parameters for FFF technology.