Experimental investigation and numerical modeling of FDM-3D printed material mechanical behavior

With the increasing use of 3D printed materials, the production technology needs to be thoroughly investigated from both experimental and numerical perspectives. Experimental analysis of 3D printed materials helps to elucidate the impact of numerous printing parameters on material behavior, thereby guiding the design of 3D printed components for specific applications. On the other hand, numerical modeling allows researchers to identify the most effective approaches to simulate the materials’ behavior, taking into account the various factors involved, such as anisotropy and the influence of printing parameters. While the literature offers extensive experimental studies on the mechanical behavior of 3D printed materials, numerical modeling remains less explored. Although recent contributions have emerged, there is still a need for comprehensive studies addressing the numerical simulation of these materials’ behavior. This study has two main objectives. The first objective is to conduct an in-depth investigation into the mechanical behavior of 3D printed PLA through a series of experimental tests on two different types of PLA. These tests focus on understanding damage mechanisms and propagation patterns. Specifically, standard tensile and flexural tests, as well as fracture tests such as compact tension (C/T) and single-edge notched bending (SENB), are performed. These tests allow to characterize the mechanical behavior of these materials, estimating their elasto-plastic parameters and identifying the various damage mechanisms that occur. The second objective is to develop a plasticity and damage model to simulate the experimentally observed mechanical behavior, including the overall stress-strain behavior, the detection of the different damage mechanisms, and their propagation timelines. Using experimental results, the model’s elasto-plastic and damage parameters are calibrated to accurately replicate the experimentally obtained behavior. The numerical study is both challenging and stimulating due to the material’s anisotropy and the simultaneous presence of multiple damage mechanisms. Numerous parameters must be considered to effectively simulate these materials’ behavior. The model’s underlying assumptions are derived from and validated through experimental tests. Comparisons between experimental and numerical results highlight the model’s effectiveness and identify areas for potential improvement, ensuring a robust framework for simulating the complex behavior of 3D printed materials.