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Design Consideration

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Designing a structure involves a series of considerations, primarily the material's ultimate strength, calculated through tests that measure changes under increased force until the material reaches its breaking point or limit. The ultimate load, where the material breaks, is divided by its original cross-sectional area, resulting in the ultimate normal stress or strength. The ultimate shearing stress is another significant factor taken into account.
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Related Experiment Video

Updated: Jul 13, 2026

Proximal Cadaveric Femur Preparation for Fracture Strength Testing and Quantitative CT-based Finite Element Analysis

Proximal Cadaveric Femur Preparation for Fracture Strength Testing and Quantitative CT-based Finite Element Analysis

Published on: March 11, 2017

Testing Protocol Development for the Fracture Toughness of Parts Built with Big Area Additive Manufacturing.

J P Garcia^1,2, L A Camacho^1,2, A I Villegas^1,2

¹Department of Aerospace and Mechanical Engineering, The University of Texas at El Paso, 500 W. University Ave, El Paso, TX 79968, USA.

|August 29, 2024

Summary

New testing methods are needed for additive manufacturing (AM) parts due to their unique material properties. This study introduces a modernized approach to assess interlayer bonding in AM components, addressing a critical research gap.

Keywords:

digital image correlation double cantilever beam test fracture toughness large-scale additive manufacturing material extrusion

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Area of Science:

Materials Science
Mechanical Engineering
Additive Manufacturing

Background:

Traditional mechanical testing standards do not fully capture the behavior of additively manufactured (AM) parts.
Inhomogeneities like porosity and poor interlayer bonding in AM parts necessitate specialized evaluation methods.
Assessing interlayer bonding in large-scale AM is challenging with current testing protocols.

Purpose of the Study:

To address the research gap in evaluating interlayer bonding for thermoplastic material extrusion AM.
To quantify interlayer bonding using fracture toughness via Mode I double cantilever beam (DCB) testing.
To introduce a modernized testing methodology incorporating Digital Image Correlation (DIC).

Main Methods:

Mode I double cantilever beam (DCB) testing was performed on thermoplastic matrix composites fabricated using Big Area Additive Manufacturing (BAAM).
The study investigated the influence of notch type and deflection speed on fracture toughness measurements.
Digital Image Correlation (DIC) was integrated to capture precise displacement and load data autonomously.

Main Results:

The research examined the effects of two notch types and three deflection speeds on DCB test outcomes.
The modernized methodology, utilizing DIC, provided simultaneous, non-invasive data acquisition.
Results highlight differences in mechanical response influenced by testing parameters and AM-specific characteristics.

Conclusions:

Existing standards are insufficient for accurately assessing the mechanical properties of AM parts.
The developed DCB testing method with DIC offers a more precise way to evaluate interlayer bonding in AM materials.
This work provides a foundation for developing AM-specific standards for mechanical testing and material characterization.