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 part
Infill optimization
Topology optimization
Experimental 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