PSI - Issue 34

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ScienceDirect

Procedia Structural Integrity 34 (2021) 87–92 Structural Integrity Procedia 00 (2021) 000–000 Structural Integrity Procedia 00 (2021) 000–000

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© 2021 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 the scientific committee of the Esiam organisers Abstract Additive manufacturing provides the possibility to manufacture parts on demand and o ff ers 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 e ff ective 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 sti ff er and stronger parts, an important step towards the practical application of FFF to structurally loaded components. c 2021 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http: // creativecommons.org / licenses / by-nc-nd / 4.0 / ) er-review under responsibility of the scientific committee of the Esiam organisers. Keywords: Fused Filament Fabrication; Structurally loaded part; Infill Optimization; Topology Optimization; Experimental Validation Abstract Additive manufacturing provides the possibility to manufacture parts on demand and o ff ers 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 e ff ective 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 sti ff er and stronger parts, an important step towards the practical application of FFF to structurally loaded components. c 2021 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http: // creativecommons.org / licenses / by-nc-nd / 4.0 / ) Peer-review under responsibility of the scientific committee of the Esiam organisers. Keywords: Fused Filament Fabrication; Structurally loaded part; Infill Optimization; Topology Optimization; Experimental Validation The second European Conference on the Structural Integrity of Additively Manufactured Materials Optimization and Redesign of a Structurally Loaded Fused Filament Fabrication Component: Numerical and Experimental Validation The second European Conference on the Structural Integrity of Additively Manufactured Materials Optimization and Redesign of a Structurally Loaded Fused Filament Fabrication Component: Numerical and Experimental Validation Sanne van den Boom ∗ , Sander Dragt, Dennis van Veen, Etienne van Daelen, Julius Berens Netherlands Institute for Applied Scientific Research (TNO), Leeghwaterstraat 44-46, 2628 CA, Delft, The Netherlands Sanne van den Boom ∗ , Sander Dragt, Dennis van Veen, Etienne van Daelen, Julius Berens Netherlands Institute for Applied Scientific Research (TNO), Leeghwaterstraat 44-46, 2628 CA, Delft, The Netherlands

1. Introduction 1. Introduction

Fused Filament Fabrication (FFF) is rapidly gaining popularity as a manufacturing technique because it provides as-needed production of parts and tremendous design freedom. However, application to critical components remains a challenge as the strength of 3-D printed parts is di ffi cult to control and predict. In this work we aim to investigate the use of FFF for highly loaded parts by analyzing a ladder step, optimizing its design, and experimentally verifying the results. Using homogenized numerical models and commercially available tools we generate two designs based on the original fused filament fabrication design provided to us by the Expertise Centrum Additive Manufacturing (ECAM). Fused Filament Fabrication (FFF) is rapidly gaining popularity as a manufacturing technique because it provides as-needed production of parts and tremendous design freedom. However, application to critical components remains a challenge as the strength of 3-D printed parts is di ffi cult to control and predict. In this work we aim to investigate the use of FFF for highly loaded parts by analyzing a ladder step, optimizing its design, and experimentally verifying the results. Using homogenized numerical models and commercially available tools we generate two designs based on the original fused filament fabrication design provided to us by the Expertise Centrum Additive Manufacturing (ECAM).

2452-3216 © 2021 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 the scientific committee of the Esiam organisers 10.1016/j.prostr.2021.12.013 ∗ Corresponding author. E-mail address: sanne.vandenboom@tno.nl 2210-7843 c 2021 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http: // creativecommons.org / licenses / by-nc-nd / 4.0 / ) Peer-review under responsibility of the scientific committee of the Esiam organisers. ∗ Corresponding author. E-mail address: sanne.vandenboom@tno.nl 2210-7843 c 2021 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http: // creativecommons.org / licenses / by-nc-nd / 4.0 / ) Peer-review under responsibility of the scientific committee of the Esiam organisers.