PSI - Issue 61

Albert E. Patterson et al. / Procedia Structural Integrity 61 (2024) 148–155 Author name / Structural Integrity Procedia 00 (2024) 000–000

152

5

Table 2. Experimental design and results. Each case was replicated three times for a total of n = 72.

Fracture Load (N) Mean Stdev

Combination Material

Nozzle Size Layout Pattern

1 2 3 4 5 6 7 8 9

ABS

0.6mm 0.6mm

R45 R45 R45 R45 R45 R45 R90 R90 R90 R90 R90 R90

384.6 621.3 688.6 490.4 583.7 766.5 452.9 542.4 672.8 387.8 582.2 650.1 338.1 525.0 563.1 335.1 557.9 579.9 538.6 828.2 524.2 752.4 850.6

14.1 58.5 23.4 11.9 53.8 32.9 12.6 67.4 55.3 34.0 12.2 30.3 14.2 16.6 22.7 11.1 35.7 36.4 24.9 35.3 44.6 26.8 7.8

PC

PLA 0.6mm

ABS

0.8mm 0.8mm

PC

PLA 0.8mm

ABS

0.6mm 0.6mm

PC

PLA 0.6mm

ABS

0.8mm 0.8mm

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

PC

PLA 0.8mm

ABS

0.6mm 0.6mm

Gyroid Gyroid Gyroid Gyroid Gyroid Gyroid

PC

PLA 0.6mm

ABS

0.8mm 0.8mm

PC

PLA 0.8mm

ABS

0.6 mm Concentric 0.6 mm Concentric

PC

361.2 153.0

PLA 0.6 mm Concentric

ABS

0.8 mm Concentric 0.8 mm Concentric

PC

PLA 0.8 mm Concentric

(a)

(b) Concentric PC Cases 0.6 Concentric 0.8 Concentric

0 100 200 300 400 500 600 700 800 900

Maximum Force at Fracture (N)

1

2

3

Replication

Fig. 4. (a) main e ff ects plot for the three factors and (b) the

4.2. Layout E ff ects

The impact of the layout is very clear when comparing the weakest and strongest layout combinations, as shown in Figure 5a. Even removing the very extreme case of the two concentric PC combinations, the di ff erence based just on the layout is striking. An analysis of the layouts (averaging the values between the nozzle sizes), as shown in Figure 5b indicates that most of the e ff ect (as indicated in the main e ff ects plot) is due to the layout adjustments. The PC samples most likely do not show the same extreme e ff ect due both to the very brittle material and the huge di ff erence in performance across the PC concentric samples. When looking at both the toolpath for the 0.6 mm concentric samples, it is clear that this specific combination of nozzle size and layout introduced an unusual amount of defects into the part