Seenivasan Soundararajan

The influence of ultra‐high printing speed (40–490 mm/s) on the mechanical response, production efficiency, and fracture characteristics of carbon fiber‐reinforced polylactic acid (PLA‐CF) composites created through fused filament fabrication was examined, focusing on the less investigated range exceeding 300 mm/s. Samples featuring two triply periodic minimal surface (TPMS) infill designs, TPMS‐D and Gyroid, were fabricated at nine distinct printing speeds, maintaining a consistent extrusion temperature of 245°C and a bed temperature of 55°C. The tensile properties, printing time, and fracture surfaces were thoroughly examined. The tensile strength increased with the speed until reaching an optimal value, measuring 35.79 MPa for TPMS‐D (290 mm/s) and 45.74 MPa for Gyroid (210 mm/s) before being reduced at the highest speeds. The two‐way ANOVA revealed significant effects of infill architecture and printing speed on tensile strength ( p < 0.001). The covariance study demonstrated that the Gyroid architecture outperforms TPMS‐D in strength due to its topology rather than material volume. The duration of printing time was lowered by around 70% across all speed categories, achieving peak efficiency at the highest speed tested (490 mm/s). The findings suggest that the optimal range for peak tensile performance lies between 210 and 290 mm/s, with increased rates enhancing throughput. The efficiency of PLA‐CF TPMS‐D and Gyroid configurations at speeds reaching 490 mm/s offers practical directives for composite additive manufacturing on an industrial level.