Print Email Facebook Twitter Optimization and redesign of a structurally loaded fused filament fabrication component Title Optimization and redesign of a structurally loaded fused filament fabrication component: Numerical and experimental validation - Preprint - Author van den Boom, S.J. Dragt, R.C. van Veen, D. van Daelen, E.C.M. Berens, J. Publication year 2021 Abstract Additive manufacturing provides the possibility to manufacture parts on demand and offers tremendous form freedom compared to traditional manufacturing methods. However, Fused Filament Fabrication (FFF) is not yet widely used for highly structurally loaded parts, as their strength is hard to control and to predict. In this work we aim to analyze, design and optimize a highly structurally loaded FFF manufactured PET-G ladder step and to experimentally verify the results. Finite element analysis is used to predict the mechanical behavior of the parts, and computational homogenization is used to find the effective material properties of infills at various densities. Additionally, topology optimization is employed to redistribute infill densities and to create optimized designs for increased performance. Experimental verification is performed on all designs. It is found that the numerical analysis can predict the mechanical behavior, and that topology optimization techniques lead to stiffer and stronger parts, an important step towards the practical application of FFF to structurally loaded components. Subject Fused Filament Fabrication (FFF)Structurally loaded partInfill optimizationTopology optimizationExperimental validation To reference this document use: http://resolver.tudelft.nl/uuid:c94805dd-e406-461e-8ccc-934f2f86a62c TNO identifier 958055 Report number TNO 0100336559 Source Structural Integrity Procedia Bibliographical note The second European Conference on the Structural Integrity of Additively Manufactured Materials (ESIAM), Virtual Conference, 8-10 September 2021 Document type article Files To receive the publication files, please send an e-mail request to TNO Library.