Comparative Analysis of AWJM Performance in FFF-Printed PLA and PLA–CF: Influence of Process Parameters and Cutting Regions

Abstract

Additive manufacturing by Fused Filament Fabrication (FFF) enables the fabrication of complex polymer components, although limitations in surface quality and dimensional accuracy often require post-processing. Abrasive water jet machining (AWJM) is a non-thermal technique suitable for improving surface integrity in polymers and composites without inducing thermal damage. This study investigates the AWJM performance on FFF-printed polylactic acid (PLA) and carbon-fiber-reinforced PLA (PLA–CF), focusing on the influence of water pressure (WP), traverse feed rate (TFR), and abrasive mass flow rate (AMFR). A full factorial design was implemented, and surface integrity was evaluated through surface roughness (Ra) and kerf taper (T), considering their variation across characteristic cutting regions: initial damage region (IDR), smooth cutting region (SCR), and rough cutting region (RCR). Results show that WP and TFR are the dominant parameters, while AMFR has a limited effect within the studied range. The SCR exhibits the lowest roughness, whereas the RCR shows significant degradation due to energy loss. Both materials present similar behavior, with only minor improvements in PLA–CF. ANOVA confirms that process parameters have a stronger influence than material type, providing useful criteria for AWJM optimization in FFF polymers.