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Projection-Based Simulation Method for Robotic 3D Printing of Large-Scale Polymer Composite Structures.

Yuen Xia¹, Kil-Sung Lee², Sung Kyu Ha¹

¹Department of Mechanical Engineering, Hanyang University, 222 Wangsimri-ro, Seonjong, Seoul 04763, Republic of Korea.

|June 13, 2025

Summary

This study presents a new method to accurately predict the structural behavior of fused deposition modeling (FDM) printed composites by mapping fiber orientations into finite element models. The approach improves simulation accuracy for anisotropic materials used in additive manufacturing.

Keywords:

characterization of material properties fused deposition modeling (FDM)large structure 3D printing projection method short fiber-reinforced polymer composites

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Area of Science:

Materials Science
Mechanical Engineering
Additive Manufacturing

Background:

Additive manufacturing (AM) of composites is advancing rapidly.
Accurate structural behavior prediction of AM parts is crucial.
Existing finite element methods (FEM) often oversimplify material anisotropy from printing paths.

Purpose of the Study:

To develop a projection-based method for mapping toolpath-defined fiber orientations into FEM.
To accurately represent the anisotropic mechanical behavior of FDM-printed composites.
To validate the method by simulating a large-scale printed structure.

Main Methods:

Experimental characterization of carbon fiber-reinforced ABS mechanical properties (elastic moduli, tensile strengths) in multiple directions.
Development of a projection-based method to integrate fiber orientation data into FEM.
Implementation and validation of the FEM model using a 20m-long printed ship structure.

Main Results:

Experimental data confirmed strong anisotropy in mechanical properties (elastic moduli 3.2-9.8 GPa, tensile strengths 20-81 MPa).
Shear modulus and strength were determined from off-axis tests (1.17 GPa and 10.9 MPa).
FE model prediction of mid-span deflection showed a 5% difference from experimental results (2.19 mm vs. 2.08 mm).

Conclusions:

The proposed projection-based method accurately simulates the structural behavior of FDM-printed composites.
The method effectively captures material anisotropy crucial for AM parts.
While facing challenges with highly irregular geometries, it offers a scalable solution for accurate composite simulations.