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Towards realistic numerical modelling of thin strut-based 3D-printed structures

Dash, Satabdee LU and Nordin, Axel LU (2023) In Proceedings of the Design Society: DESIGN Conference 3. p.3591-3600
Abstract
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... (More)
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. (Less)
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author
and
organization
publishing date
type
Chapter in Book/Report/Conference proceeding
publication status
published
subject
keywords
Design for Additive Manufacturing (DfAM), Numerical modelling, 3D printing, Lattice structures, Computational design methods
host publication
Proceedings of the International Conference on Engineering Design (ICED23). 24-28 JULY 2023, Bordeaux, France
series title
Proceedings of the Design Society: DESIGN Conference
volume
3
pages
10 pages
publisher
Design Society
external identifiers
  • scopus:85165489637
ISSN
2633-7762
DOI
10.1017/pds.2023.360
language
English
LU publication?
yes
id
4cff5207-c8a8-43de-a0ea-9c915421df36
date added to LUP
2023-08-14 11:45:42
date last changed
2023-12-21 15:06:51
@inproceedings{4cff5207-c8a8-43de-a0ea-9c915421df36,
  abstract     = {{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.}},
  author       = {{Dash, Satabdee and Nordin, Axel}},
  booktitle    = {{Proceedings of the International Conference on Engineering Design (ICED23). 24-28 JULY 2023, Bordeaux, France}},
  issn         = {{2633-7762}},
  keywords     = {{Design for Additive Manufacturing (DfAM); Numerical modelling; 3D printing; Lattice structures; Computational design methods}},
  language     = {{eng}},
  pages        = {{3591--3600}},
  publisher    = {{Design Society}},
  series       = {{Proceedings of the Design Society: DESIGN Conference}},
  title        = {{Towards realistic numerical modelling of thin strut-based 3D-printed structures}},
  url          = {{http://dx.doi.org/10.1017/pds.2023.360}},
  doi          = {{10.1017/pds.2023.360}},
  volume       = {{3}},
  year         = {{2023}},
}