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TOWARDS REALISTIC NUMERICAL MODELLING OF THIN STRUT-BASED 3D-PRINTED STRUCTURES

Published online by Cambridge University Press:  19 June 2023

Satabdee Dash  and
Axel Nordin
Satabdee Dash*
Affiliation:
Lund University
Axel Nordin
Affiliation:
Lund University
*
Dash, Satabdee, Lund University, Sweden, satabdee.dash@design.lth.se

Abstract

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The as-built geometry and material properties of parts manufactured using Additive Manufacturing (AM) can differ significantly from the as-designed model and base material properties. These differences can be more pronounced in thin strut-like features (e.g., in a lattice structure), making it essential to incorporate them when designing for AM and predicting their structural behaviour. Therefore, the aim of this study is to develop a numerical model with realistic characteristics based on a thin strut-based test artefact and to use it accurately for estimating its compressive strength. Experiments on test samples produced by selective laser sintering in PA 1101, are used to calculate geometrical deviations, Young's modulus, and yield strength, which are used to calibrate the numerical model. The experimental and numerical results show that the numerical model incorporating geometrical and material deviations can accurately predict the peak load and the force-displacement behaviour. The main contributions of this paper include the design of the test artefact, the average geometrical deviation of the struts, the measured material data, and the developed numerical model.

Keywords

3D printingDesign for Additive Manufacturing (DfAM)Lattice structuresComputational design methodsNumerical modelling
Type
Article
Information
Proceedings of the Design Society , Volume 3: ICED23 , July 2023 , pp. 3591 - 3600
Creative Commons
Creative Common License - CCCreative Common License - BYCreative Common License - NCCreative Common License - ND
This is an Open Access article, distributed under the terms of the Creative Commons Attribution-NonCommercial-NoDerivatives licence (http://creativecommons.org/licenses/by-nc-nd/4.0/), which permits non-commercial re-use, distribution, and reproduction in any medium, provided the original work is unaltered and is properly cited. The written permission of Cambridge University Press must be obtained for commercial re-use or in order to create a derivative work.
Copyright
The Author(s), 2023. Published by Cambridge University Press

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