Static Response and Failure Prediction of Anisotropic Material Extrusion Polymer Parts

Abstract

The integration of additive manufacturing techniques has redefined the landscape of component manufacture, offering cost-effective and efficient alternatives to conventional manufacturing methods. This study delves into the application of an affordable MEx( MaterialExtrusion) 3D printer for producing PEEK (Poly-Ether-Ether-Ketone) polymer specimens designed for mechanical testing. The central aim is to investigate the feasibility of replacing non-structural metal aircraft components with MEx 3D printed PEEK counterparts. The major advantage of MEx 3D printing lies in its ability to manufacture complex components without the need for molds or casts, leading to substantial cost reductions and accelerated development timelines. However, the inherent anisotropic nature of MExproduced components poses a challenge. The layer-wise filament deposition gives inter-layer air gaps, introducing mechanical variability across different axes. To address this challenge, our research employs a novel approach by subjecting MEx printed PEEK polymer specimen to mechanical tests involving forces applied at oriented angles to the anisotropic layer. This testing method is pivotal in modeling potential split and rupture of the MEx components, as encountered in real-world aircraft applications. By utilizing the Digital Image Correlation (DIC) tool to analyze full-field strain measurements and capture the elastic mechanical response of PEEK polymer specimen, our study establishes a strain-based failure criterion that defines the critical strain failure boundary.