This research examines the influence of infill pattern and infill density on Fused Deposition Modelling (FDM) printed nylon carbon fibre (CF) composite cylinders' strength. Nylon CF composites have been extensively researched regarding their strength, but relatively few studies have addressed the influence of design of the internal structure (infill pattern and density) on their strength, mode of failure, and energy absorption. This research tries to fill this research gap by identifying optimal infill strategies to achieve maximum strength-to-weight ratio and energy absorption in compression of FDM-printed cylinders. This research categorizes infill patterns as 2D types (Line, Grid, Cross, Tri-Hex) and 3D types (Cubic, Gyroid, Octet, Cross 3D), and infill densities of 40%, 60%, 80%, and 100%. Results indicate that 2D patterns, that i, Tri-Hex and Grid, possess higher strength-to-weight ratios than 3D patterns, with Nylon CF Tri-Hex possessing ɸ = 944.67 N/g at 80% density. Higher infill densities (80% and 100%) enhanced the energy absorption, with Grid infill possessing maximum energy absorption at 3802.50 kJ/m3 at 80% density. The mode of failure was found to be infill pattern dependent. Tri-Hex and Grid structures failed progressively by bending, while Cubic and Gyroid failed due to stresses at the point edges. The reported findings can be beneficial for aerospace, automobile, robotics, and medical equipment industries, which need strong, yet light structures.
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