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<p>The increasing prevalence of additive manufacturing with material extrusion necessitates a rigorous understanding of the process-property-performance relationship in 3D-printed polymers, particularly the consistency of mechanical properties despite manufacturing anomalies. This study experimentally and analytically investigates the variability in stiffness and tensile strength of polylactic acid (PLA) samples fabricated as flat layers and isogrids. Experimental tensile testing revealed comparable stiffness and strength across most configurations, irrespective of manufacturing-induced anomalies. Analytical models that were statistically penalized to account for manufacturing variability, considering randomized cross-sectional areas, demonstrated excellent agreement with the experimentally determined stiffness variability. Furthermore, the tensile strength of the flat layer was accurately predicted using the Tresca criterion, while Cohesive Zone Modelling effectively captured the failure behavior of the isogrid. Despite its linear assumptions, this integrated experimental-statistical framework offers a viable approach for predicting the mechanical response and assessing the reliability of additively manufactured components.</p>

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Exploring mechanistic anomalies in additively manufactured structures

  • 期刊论文

  • 发表日期：

    2026年1月9日

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  • George Youssef,
  • Mario Álvarez-Blanco,
  • Celia Rufo-Martín,
  • Diego Infante-García,
  • Miguel Marco

摘要

The increasing prevalence of additive manufacturing with material extrusion necessitates a rigorous understanding of the process-property-performance relationship in 3D-printed polymers, particularly the consistency of mechanical properties despite manufacturing anomalies. This study experimentally and analytically investigates the variability in stiffness and tensile strength of polylactic acid (PLA) samples fabricated as flat layers and isogrids. Experimental tensile testing revealed comparable stiffness and strength across most configurations, irrespective of manufacturing-induced anomalies. Analytical models that were statistically penalized to account for manufacturing variability, considering randomized cross-sectional areas, demonstrated excellent agreement with the experimentally determined stiffness variability. Furthermore, the tensile strength of the flat layer was accurately predicted using the Tresca criterion, while Cohesive Zone Modelling effectively captured the failure behavior of the isogrid. Despite its linear assumptions, this integrated experimental-statistical framework offers a viable approach for predicting the mechanical response and assessing the reliability of additively manufactured components.