The Influence of Filament Orientation on Tensile Stiffness in 3D Printed Structures—Numerical and Experimental Studies

The present study provides a thorough analysis of the influence of filament orientation on the tensile stiffness of 3D-printed structures. This exploration employs a combination of numerical simulations and experimental trials, providing an extensive understanding of additive manufacturing, particularly 3D printing. This process involves layer-by-layer material deposition to produce three-dimensional objects. The examination specifically targets PLA-based 3D printed structures created using Fused Filament Fabrication (FFF) technology and subjects them to rigorous evaluations using a universal tensile testing machine. Additionally, this approach combines Representative Volume Element (RVE) and Classical Lamination Theory (CLT) techniques to extrapolate the mechanical properties of the test material. Although the initial methodology faces challenges in determining the shear modulus with precision, an in-depth investigation results in enhanced accuracy. Furthermore, this study introduces a parametric RVE numerical method, demonstrating its resilience in handling sensitivity to shear modulus. A comparative study of results derived from both the analytical methods and experimental trials involving five series of samples with varied layups reveals that the newly proposed numerical method shows a stronger correlation with the experimental outcomes, delivering a relative error margin of up to 8%.