Failure models for fused filament fabrication 3D-printed specimens

Abstract

Fused filament fabrication (FFF) is an additive manufacturing technique most commonly used in the 3D printing of thermoplastics. It enables the prompt manufacturing of custom-made parts with minimum molding and tooling costs. The lack of comprehensive studies on FFF failure models has hindered its widespread industrial use. This chapter aims to introduce novel FFF failure models. In order to do that, different types of analysis are briefly discussed. Next, an overview of isotropic, anisotropic, orthogonal, mono-clinical, and transversely isotropic materials is provided by looking into their assumptions and compliance matrices. After drawing the similarities between a 3D-printed FFF part and a composite, the classical laminate theory is discussed, and the theoretical elastic modulus is derived. Through a brief literature survey, it is concluded that the theoretical elastic modulus is accurate for engineering purposes. In the end, the failure modes are explored and five failure models for FFF specimens are put forward including two linear interpolation models, a modification to the Tsai-Hill model, a quadratic failure model, and a conservative model. © 2024 Elsevier Inc. All rights are reserved including those for text and data mining AI training and similar technologies.