Additively manufactured polymer parts are often designed like composite sandwich structures. In this work, sandwich beam-like specimens with hexagonal, triangular and rectangular infills were manufactured with different infill densities. An influence of the shape of the infill on the overall stiffness was observed. The bending stiffness of the hexagonal specimens was between 13% and 25% lower than that of the other two cases that instead showed similar performances. Numerical simulations were performed using both shell and solid elements for the infill, to check if it was possible to model the differences observed experimentally. All simulations lead to accurate bending stiffness predictions, except for the rectangular infills with higher infill densities, for which overprediction between 20% and 25% was obtained. Based on these results, strategies for the finite element analysis of additively manufactured composite structures are discussed.
El MoumenATarfaouiMLafdiK. Additive manufacturing of polymer composites: processing and modeling approaches. Compos B: Eng2019; 171: 166–182.
2.
HuangSHLiuPMokasdarA, et al.Additive manufacturing and its societal impact: a literature review. Int J Adv Manuf Technol2013; 67: 1191–1203.
3.
ParandoushPLinD. A review on additive manufacturing of polymer-fiber composites. Compos Struct2017; 182: 36–53.
4.
DizonJRCEsperaAHChenQ, et al.Mechanical characterization of 3D-printed polymers. Addit Manuf2018; 20: 44–67.
5.
AhnSHMonteroMOdellD, et al.Anisotropic material properties of fused deposition modeling ABS. Rapid Prototyp J2002; 8: 248–257.
6.
ChacónJMCamineroMAGarcía-PlazaE, et al.Additive manufacturing of PLA structures using fused deposition modelling: effect of process parameters on mechanical properties and their optimal selection. Mater Des2017; 124: 143–157.
7.
CasavolaCCazzatoAMoramarcoV, et al.Orthotropic mechanical properties of fused deposition modelling parts described by classical laminate theory. Mater Des2016; 90: 453–458.
8.
RankouhiBJavadpourSDelfanianF, et al.Failure analysis and mechanical characterization of 3D printed ABS with respect to layer thickness and orientation. J Fail Anal Preven2016; 16: 467–481.
9.
CarneiroOSSilvaAFGomesR. Fused deposition modeling with polypropylene. Mater Des2015; 83: 768–776.
10.
SoodAKOhdarRKMahapatraSS. Parametric appraisal of mechanical property of fused deposition modelling processed parts. Mater Des2010; 31: 287–295.
11.
ZhongWLiFZhangZ, et al.Short fiber reinforced composites for fused deposition modeling. Mater Sci Eng A2001; 301: 125–130.
12.
TekinalpHLKuncVVelez-GarciaGM, et al.Highly oriented carbon fiber-polymer composites via additive manufacturing. Compos Sci Technol2014;105:144–150.
13.
NingFCongWQiuJ, et al.Additive manufacturing of carbon fiber reinforced thermoplastic composites using fused deposition modeling. Compos B Eng2015; 80: 369–378.
14.
JiangDSmithDE. Anisotropic mechanical properties of oriented carbon fiber filled polymer composites produced with fused filament fabrication. Addit Manuf2017; 18: 84–94.
15.
NingFCongWHuY, et al.Additive manufacturing of carbon fiber-reinforced plastic composites using fused deposition modeling: effects of process parameters on tensile properties. J Compos Mater2017; 51: 451–462.
16.
Naranjo-LozadaJAhuett-GarzaHOrta-CastañónP, et al.Tensile properties and failure behavior of chopped and continuous carbon fiber composites produced by additive manufacturing. Addit Manuf2019; 26: 227–241.
Fernandez-VicenteMCalleWFerrandizS, et al.Effect of infill parameters on tensile mechanical behavior in desktop 3D printing. 3D Print Addit Manuf2016; 3: 183–192.
21.
LiTWangL. Bending behavior of sandwich composite structures with tunable 3D-printed core materials. Compos Struct2017; 175: 46–57.
22.
GibsonLJAshbyMF. Cellular Solids: Structure and Properties. 2nd ed. Cambridge, UK: Cambridge University Press, 1997.
23.
TangHChenHSunQ, et al.Experimental and computational analysis of structure-property relationship in carbon fiber reinforced polymer composites fabricated by selective laser sintering. Compos Part B Eng2021; 204: 108499.
24.
RajuBHiremathSRRoy MahapatraD. A review of micromechanics based models for effective elastic properties of reinforced polymer matrix composites. Compos Struct2018; 204: 607–619. DOI: 10.1016/j.compstruct.2018.07.125.
25.
ChoiJYKortschotMT. Stiffness prediction of 3D printed fiber-reinforced thermoplastic composites. Rapid Prototyp J2019; 26: 549–555.
26.
EN ISO 527-1. Plastics. Determination of Tensile Properties. Part 1, General Principles. Geneva, CH: ISO, 1997.
27.
EN ISO 178. Plastics — Determination of Flexural Properties. Geneva, CH: ISO, 2019.
28.
BarberoEJ. Introduction to Composite Materials Design. II Edition. Boca Raton (FL, US): CRC Press, 2011.
29.
NarulaSCWellingtonJF. Prediction, linear regression and the minimum sum of relative errors. Technometrics1977; 19: 185–190.
30.
GholamyAKreinovichV. How to use absolute-error-minimizing software to minimize relative error: practitioner’s guide. Int Math Forum2017; 12: 763–770.
31.
AbràmoffMDMagalhãesPJRamSJ. Image processing with imageJ. Biophotonics Int2004; 11: 36–41.
32.
YeolePHassenAAKimS, et al.Mechanical characterization of high-temperature carbon fiber-polyphenylene sulfide composites for large area extrusion deposition additive manufacturing. Addit Manuf2020; 34: 101255.
33.
DialamiNChiumentiMCerveraM, et al.Numerical and experimental analysis of the structural performance of AM components built by fused filament fabrication. Int J Mech Mater Des2020; 17: 225–244.
