OBRABOTKAMETALLOV Vol. 28 No. 3 2026 343 MATERIAL SCIENCE References 1. Chunxu L., Pisignano D., Zhao Y., Xue J. Advances in medical applications of additive manufacturing. Engineering, 2020, vol. 6 (11), pp. 1222–1231. DOI: 10.1016/j.eng.2020.02.018. 2. Kirichek A.V., Solovyev D.L., Yashin A.V., Silantyev S.A., Aborkin A.V., Novikov M.A. Issledovanie anizotropii svoistv sintezirovannykh metallicheskikh materialovWAAM-metodom [Anisotropy of properties in metal materials fabricated by wire arc additive manufacturing (WAAM)]. Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science, 2025, vol. 27, no. 4, pp. 206–220. DOI: 10.17212/1994-63092025-27.4-206-220. Investigation of the eff ect of additive manufacturing process parameters on the fabrication of a 3D-printed talus bone prototype Devendra Agrawal 1, a, *, Sushil Patil 1, b, Nitin Ambhore 2, c, Dinesh Washimkar 2, d, Dhroov Agrawal 3, e 1 Department of Mechanical Engineering, S.V.P.M’S College of Engineering Malegaon (Bk.), SPPU, Pune, 413115, Maharashtra, India 2 Department of Mechanical Engineering, Vishwakarma Institute of Technology, SPPU, Pune, 411048, Maharashtra, India 3 Department of Bachelor of Medicine & Bachelor of Surgery, KD Medical College, Mathura, 281401, Uttar Pradesh, India Obrabotka metallov - Metal Working and Material Science Journal homepage: http://journals.nstu.ru/obrabotka_metallov Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science. 2026 vol. 28 no. 3 pp. 331–344 ISSN: 1994-6309 (print) / 2541-819X (online) DOI: 10.17212/1994-6309-2026-28.3-331-344 ART I CLE I NFO Article history: Received: 28 May 2026 Revised: 13 June 2026 Accepted: 14 August 2026 Available online: 15 September 2026 Keywords: 3D printing Additive manufacturing Fused deposition modelling Polylactic acid Talus bone Grey relational analysis Prototype ABSTRACT Introduction. Additive manufacturing, and in particular fused deposition modelling (FDM), enables the fabrication of geometrically complex parts without dedicated tooling, which is especially valuable for patientspecifi c biomedical devices. The mechanical performance of polylactic acid (PLA) parts, however, depends strongly on the combination of printing parameters, and the available data on the joint infl uence of layer thickness, nozzle temperature, and material fl ow rate on the full set of strength characteristics remain fragmentary, which complicates process selection for anatomical prototypes. The aim of this work is to determine the optimum combination of FDM printing parameters for PLA parts that maximizes the integrated strength response, and to fabricate, using the identifi ed settings, a full-scale patient-specifi c prototype of the human talus bone from computed tomography data. Materials and methods. A Taguchi L27 orthogonal array was implemented with three levels of layer thickness (0.1–0.3 mm), nozzle temperature (190–210 °C), and material fl ow rate (95–105%). Tensile strength and Young’s modulus were determined in accordance with ASTM D638–22 on a universal testing machine at a crosshead speed of 5 mm/min; specifi c fracture energy (toughness) was measured according to ASTM D256–23 using a notched Izod pendulum impact tester. The signifi cance of the factors was evaluated by analysis of variance (ANOVA), and multi-response optimization was performed by grey relational analysis (GRA). The geometry of the fabricated prototype was inspected on a coordinate measuring machine. Results and discussion. Material fl ow rate was found to be the dominant factor for tensile strength (contribution of 50.3 %) and for toughness (92.9%), whereas Young’s modulus is governed primarily by layer thickness. The highest grey relational grade (0.853) was obtained at a layer thickness of 0.1 mm, a nozzle temperature of 210 °C, and a fl ow rate of 105%. The dimensional deviations of the fabricated prototype from the CT data did not exceed 0.2 mm, which confi rms its suitability as a master model for the subsequent manufacture of an implant from a biocompatible material. For citation: Agrawal D., Patil S., Ambhore N., Washimkar D., Agrawal D. Investigation of the eff ect of additive manufacturing process parameters on the fabrication of a 3D-printed talus bone prototype. Obrabotka metallov (tekhnologiya, oborudovanie, instrumenty) = Metal Working and Material Science, 2026, vol. 28, no. 3, pp. 331–344. DOI: 10.17212/1994-6309-2026-28.3-331-344. (In Russian). ______ * Corresponding author Devendra Agrawal, Ph.D. (Engineering), Associate Professor S.V.P.M’S College of Engineering Malegaon (Bk.), Savitribai Phule Pune University, Pune, Maharashtra, India. Tel.: +91-9421054282, e-mail: dpagrawal@engg.svpm.org.in a https://orcid.org/0000-0002-2477-1841, dpagrawal@engg.svpm.org.in; b https://orcid.org/0000-0002-0547-6038, sspatil@engg.svpm.org.in; c https://orcid.org/0000-0001-8468-8057, nitin.ambhore@vit.edu; d https://orcid.org/0000-0002-1312-2619, dinesh.washimkar@vit.edu; e https://orcid.org/0009-0000-8547-9484, dhroovagrawal109@gmail.com
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