Numerical Simulations of Components Produced by Fused Deposition 3D Printing

Area of Science:

• Materials Science
• Mechanical Engineering
• Additive Manufacturing

Background:

• Fused deposition modeling (FDM) 3D printing is increasingly utilized due to enhanced material properties from fiber reinforcement.
• Component mechanical properties are influenced by both filament characteristics and printing parameters.
• Accurate prediction of mechanical performance is crucial for design optimization.

Purpose of the Study:

• To develop a predictive tool for designers to estimate the mechanical properties of 3D printed components using finite element analysis (FEA).
• To validate the predictive capabilities of the FEA tool through experimental testing.

Main Methods:

• Investigated two nylon-based filaments reinforced with glass and carbon fibers.
• Experimentally determined elastic material model parameters from tensile tests on dog bone specimens printed in multiple orientations.
• Utilized FEA to predict the mechanical response of simple structures (blocks) subjected to four-point bending tests.
• Compared experimental load-curvature data with numerical predictions.

Main Results:

• The developed FEA tool, using a transversely isotropic material model, accurately predicted the mechanical behavior of 3D printed components before the onset of nonlinearities.
• Experimental and numerical results for four-point bending tests showed good agreement in load-curvature relationships.
• The study confirmed the suitability of a purely elastic transversely isotropic model for predicting the behavior of FDM parts with fiber reinforcement.

Conclusions:

• A validated FEA tool can effectively predict the mechanical properties of 3D printed components made with fiber-reinforced filaments.
• The transversely isotropic material model is sufficient for accurate predictions in the elastic range.
• This predictive capability aids designers in optimizing the use of 3D printed parts in engineering applications.