PSI - Issue 77

ScienceDirect Available online at www.sciencedirect.com ScienceDirect Structural Integrity Procedia 00 (2026) 000–000 Available online at www.sciencedirect.com ScienceDirect Structural Integrity Procedia 00 (2026) 000–000 Available online at www.sciencedirect.com Structural Integrity Procedia 00 (2026) 000–000 Procedia Structural Integrity 77 (2026) 357–364 Available online at www.sciencedirect.com ScienceDirect

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© 2026 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of ICSI organizers Abstract Additive manufacturing (AM) using fused deposition modeling (FDM) offers unique advantages for producing complex geometries with minimal waste; however, the mechanical performance of printed polylactic acid (PLA) parts is often limited by process-induced defects, such as porosity and inter-layer delamination. Infill geometry plays a crucial role in defect formation and distribution, influencing both material efficiency and structural integrity. To address this challenge, this study utilizes X-ray computed t omography (μCT) to assess internal porosity in PLA specimens with cubic and triangular infill patterns. An image processing workflow was developed to distinguish between true material defects and intentional infill voids, enabling the precise quantification of defect count, size, and spatial distribution. μ CT-derived measurements were further used to compute effective material density, which was correlated with tensile test data to assess the influence of porosity on strength and failure modes. Results demonstrate that μ CT provides critical insights into the relationship between infill design, defect morphology, and mechanical reliability, establishing its potential as a robust tool for quality assurance in polymer-based additive manufacturing. Keywords: micro-computed tomography; additive manufacturing; PLA; infill structures; non-destructive testing. © 2026 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of ICSI organizers International Conference on Structural Integrity Application of micro-CT for characterization and analysis of 3D-printed samples produced using the FDM additive manufacturing method Pawel Madejski a, *, Isyna Izzal Muna a a Department of Power Systems and Environmental Protection Facilities, Faculty of Mechanical Engineering and Robotics, AGH University of Krakow, Al. Mickiewicza 30, 30-059 Krakow, Poland Abstract Additive manufacturing (AM) using fused deposition modeling (FDM) offers unique advantages for producing complex geometries with minimal waste; however, the mechanical performance of printed polylactic acid (PLA) parts is often limited by process-induced defects, such as porosity and inter-layer delamination. Infill geometry plays a crucial role in defect formation and distribution, influencing both material efficiency and structural integrity. To address this challenge, this study utilizes X-ray computed t omography (μCT) to assess internal porosity in PLA specimens with cubic and triangular infill patterns. An image processing workflow was developed to distinguish between true material defects and intentional infill voids, enabling the precise quantification of defect count, size, and spatial distribution. μ CT-derived measurements were further used to compute effective material density, which was correlated with tensile test data to assess the influence of porosity on strength and failure modes. Results demonstrate that μ CT provides critical insights into the relationship between infill design, defect morphology, and mechanical reliability, establishing its potential as a robust tool for quality assurance in polymer-based additive manufacturing. Keywords: micro-computed tomography; additive manufacturing; PLA; infill structures; non-destructive testing. © 2026 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of ICSI organizers International Conference on Structural Integrity Application of micro-CT for characterization and analysis of 3D-printed samples produced using the FDM additive manufacturing method Pawel Madejski a, *, Isyna Izzal Muna a a Department of Power Systems and Environmental Protection Facilities, Faculty of Mechanical Engineering and Robotics, AGH University of Krakow, Al. Mickiewicza 30, 30-059 Krakow, Poland Abstract Additive manufacturing (AM) using fused deposition modeling (FDM) offers unique advantages for producing complex geometries with minimal waste; however, the mechanical performance of printed polylactic acid (PLA) parts is often limited by process-induced defects, such as porosity and inter-layer delamination. Infill geometry plays a crucial role in defect formation and distribution, influencing both material efficiency and structural integrity. To address this challenge, this study utilizes X-ray computed t omography (μCT) to assess internal porosity in PLA specimens with cubic and triangular infill patterns. An image processing workflow was developed to distinguish between true material defects and intentional infill voids, enabling the precise quantification of defect count, size, and spatial distribution. μ CT-derived measurements were further used to compute effective material density, which was correlated with tensile test data to assess the influence of porosity on strength and failure modes. Results demonstrate that μ CT provides critical insights into the relationship between infill design, defect morphology, and mechanical reliability, establishing its potential as a robust tool for quality assurance in polymer-based additive manufacturing. Keywords: micro-computed tomography; additive manufacturing; PLA; infill structures; non-destructive testing. © 2026 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of ICSI organizers International Conference on Structural Integrity Application of micro-CT for characterization and analysis of 3D-printed samples produced using the FDM additive manufacturing method Pawel Madejski a, *, Isyna Izzal Muna a a Department of Power Systems and Environmental Protection Facilities, Faculty of Mechanical Engineering and Robotics, AGH University of Krakow, Al. Mickiewicza 30, 30-059 Krakow, Poland

* Corresponding author. Tel.: +48 617 39 59. E-mail address: madejski@agh.edu.pl * Corresponding author. Tel.: +48 617 39 59. E-mail address: madejski@agh.edu.pl

2452-3216 © 2026 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of ICSI organizers 10.1016/j.prostr.2026.01.046 2452-3216 © 2026 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of ICSI organizers 2452-3216 © 2026 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of ICSI organizers 2452-3216 © 2026 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of ICSI organizers * Corresponding author. Tel.: +48 617 39 59. E-mail address: madejski@agh.edu.pl