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

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.