Home | Mirza Faizaan

EDUCATION

2017

Bachelor of Engineering [BE]
Automobile Engineering

Dayananda Sagar College of Engineering
Bangalore, KA. IN.

2019

Master of Technology [MTech]
Automobile Engineering

Manipal Institute of Technology, MAHE
Manipal, KA. IN.

2025*

Doctor of Philosophy [PhD]

MAHE-Deakin Cotutelle PhD
MIT, MAHE, Manipal, KA. IN
Deakin University, Geelong, VIC. AU

Hello,
I am Mirza Faizaan

Dedicated materials researcher specialising in material extrusion additive manufacturing (MEX-AM) with over 5 years of experience, strongly emphasising weathering effects and establishing structure-property relationships through mechanical and material characterisation. I am passionate about meta-materials and lattice structures, particularly for lightweight structural applications. Proficient in CAD and static structural analysis, I am also familiar with ASTM standards for the mechanical characterisation of plastics. My hands-on experience includes working with single and twin-screw extruders, internal mixers, universal testing machines (UTM), and advanced techniques like optical microscopy, micro-CT, XRD, FTIR, and DSC. I also possess skills in analyzing SEM micrographs, image processing using ImageJ and GIMP, and programming in MATLAB for data visualization and analysis. In my spare time, I enjoy 3D printing as a hobby

EXPERIENCES

RESEARCH EXPERIENCE

ORCID

My research focused on the optimization and understanding the overall variance in tensile performance caused by the characteristic process induced voids of the material extrusion based additive manufacturing [MEX-AM] method, commonly called Fused Deposition Modeling [FDM]. Further, the effects of artificial weathering on MEX-AM poly(lactic) acid was explored in a time-dependent study. The degradation in tensile performance, polymer crystallinity, chemical and thermal characteristics were established over prolonged exposure to UV and relative humidity. Lastly, new frontiers in cellular infill structures were investigated as an alternative to conventional 2D infill patterns with the focused intention to lightweight parts with minimal loss in compressive strength. Here, short fibre reinforcements were looked into as a viable option to improve the MEX-AM PLA composite mechanical properties. However, due to various challenges including poor fibre-matrix adhesion and innate brittleness of the in-house produced filament, this research project was concluded and may be explored in future.

A study on the overall variance and void architecture on MEX-PLA tensile properties through printing parameter optimisation

Abstract

This study investigates the influence of printing parameters on the tensile properties and void architecture of poly(lactic) acid (PLA) parts fabricated using the fused filament fabrication (FFF) technique. Two Taguchi optimisation methods were employed to identify the optimal parameter combinations for maximising tensile performance. The results revealed a positive correlation between tensile performance and nozzle diameter (ND). Notably, the analysis of the coefficient of variance (COV) studies revealed that both tensile strength and modulus exhibited minimal variation within a tight range of 5.5%, suggesting a high degree of process consistency in achieving desired mechanical properties regardless of the chosen parameters within the investigated range. Micro-computed tomography (micro-CT) analysis was used to quantify void characteristics within the as-printed samples. Micro-CT analysis confirmed the influence of ND and layer thickness (LT) on void architecture. By establishing structure-property relationships, the study revealed that larger NDs paired with finer LTs yielded superior tensile properties due to reduced void content. This work highlights the interplay between printing parameters, void architecture, and the resulting mechanical behaviour of MEX-based PLA parts.

Link to Paper

Tensile Coupons subjected to prolonged weathering effects

Time-Dependent Structure-Property relationship of artificially weathered MEX-PLA

Abstract

This research addresses the critical need for a comprehensive understanding of the long-term environmental stability of polylactic acid (PLA), a widely utilized bio-based polymer, particularly in the context of material extrusion additive manufacturing (MEX-AM). Given the escalating demand for sustainable materials and the proliferation of MEX-AM technologies, an in-depth investigation into the degradation mechanisms of PLA under prolonged accelerated weathering conditions is warranted. This study systematically examines the temporal evolution of mechanical, chemical, and thermal properties in MEX-AM PLA tensile specimens subjected to prolonged UV+RH exposure, spanning up to 2000 hours. The findings demonstrate a time-dependent correlation between weathering exposure and material deterioration, characterized by β-scission-induced chain scission, substantial increases in crystallinity resulting in the decline in tensile strength. While the study provides valuable insights into the degradation kinetics of MEX-AM PLA, it acknowledges the inherent limitations of simulated weathering environments and emphasizes the need for further research to extrapolate these findings to outdoor weathering conditions.

Temperature cycles for UV and RH during Testing

Lightweighting through cellular structures and fibre reinforced filament for MEX-AM

Abstract

This study investigates two distinct yet interconnected avenues within material extrusion additive manufacturing (MEX-AM): the utilization of complex cellular structures for optimized lightweighting and the incorporation of discontinuous fiber reinforcements for enhanced mechanical performance. Recognizing the design flexibility of MEX-AM, particularly with polylactic acid (PLA), the research explores closed-cell cellular geometries, specifically Isomax™ (cubic+octet) and 3D Kagome, as alternatives to conventional open-cell infill patterns. Through simulation and experimental validation, the compressive strength of these structures is evaluated, revealing isotropic behavior under compressive loads despite a reduction in strength compared to solid counterparts. Furthermore, the study examines the feasibility of discontinuous fiber reinforcement by fabricating a 10%wt. bamboo fiber/PLA composite filament. Challenges encountered during filament production, including diameter instability and fiber pull-out, highlight the complexities of achieving effective fiber-matrix adhesion. This research contributes to the understanding of advanced MEX-AM techniques by exploring cellular design optimization and the limitations of discontinuous fiber reinforcement, paving the way for future investigations into improved composite fabrication and structural performance.

Effect of material extrusion process parameters on tensile performance of pristine and discontinuous fibre reinforced PLA composites: A review

Abstract

Material Extrusion Additive Manufacturing (MEAM) has witnessed significant research interest since 2009. The optimization of printing and material parameters to enhance the mechanical properties of 3D-printed parts has been the primary research objective. Among commonly used polymers, Polylactic Acid (PLA) has emerged as a preferred material due to its ease of use, biodegradability, and relatively high mechanical strength. While the incorporation of discontinuous fiber reinforcements (dFR) into PLA filaments offers the potential for improved tensile performance, existing literature suggests that their impact is often negligible or even detrimental. Furthermore, the optimization of printing parameters for MEAM-dFR composites has not been extensively studied as for pristine polymers. This review aims to investigate the influence of printing parameters on the tensile performance of various PLA-based dFRCs. Three fiber types—basalt, carbon, and wood—were selected to analyse their effects on tensile properties. A bubble chart was developed to visualize the correlations between raster angle, fiber content, layer thickness, printing speed, and extrusion temperature on the composite tensile properties. The findings highlight the importance of material selection in enhancing tensile performance. Additionally, the need for more comprehensive statistical studies on the optimization of printing parameters for MEAM-dFRCs is emphasized.

Link to Paper

PHD THESIS SUMMARY

Mirza, F., Baloor Shenoy, S., Nunna, S. et al. A study on the overall variance and void architecture on MEX-PLA tensile properties through printing parameter optimisation. Scientific Reports (2024). https://doi.org/10.1038/s41598-025-87348-2
Article in press: Faizaan, M., Shenoy, S., & Kini, C. R. et al. Impact of Lattice Geometry on Compressive Strength: A Finite Element Analysis. Target journal yet to be decided.
Paper Presented in International Conference on Computational Methods on Engineering & Health Sciences (ICCCMEH2024); December 2024.
Mirza, F., Baloor Shenoy, S., Nunna, S. et al. Effect of material extrusion process parameters on tensile performance of pristine and discontinuous fibre reinforced PLA composites: A review. Prog Addit Manuf (2024). https://doi.org/10.1007/s40964-024-00825-4
Faizaan, M., Shenoy, S., & Kini, C. R. (2024). Tensile and Flexural Performance of Hybrid FDM and Compression Moulded PLA/Basalt Biocomposite. In Materials Science Forum (Vol. 1120, pp. 77–84). Trans Tech Publications, Ltd. https://doi.org/10.4028/p-duyo7m
Poster presented at the IFM Research Conference, Geelong, VIC, AU, titled ‘To what extent do FDM printing parameters really affect PLA tensile performance?’. November 2023.
Paper Presented in 3rd International Conference on Advances in Material Sciences 2023 (ICAMS2023); May 2023.
Design Patent: “Tensile sample mount for accelerated weathering chamber” bearing design number: 383798-001

EDUCATION

2017

2019

2025*

Hello, I am Mirza Faizaan

EXPERIENCES

RESEARCH EXPERIENCE

A study on the overall variance and void architecture on MEX-PLA tensile properties through printing parameter optimisation

PHD THESIS SUMMARY

RESEARCH OUTPUT

Hello,
I am Mirza Faizaan