Purpose: The purpose on this article is to study the failure of FDM printed ABS by exhibiting an exhaustive crack growth analysis mainly based on raster angle parameter. Design/methodology/approach: Two approaches have been developed in this study; On one hand, mechanical experiments were carried out to determine the critical stress intensity factor KIC. On the other hand, numerical analysis was used to predict the paths within the part as well as the crack propagation. Findings: This work has clearly shown the effect of raster angle on the damage mechanism of the ABS printed by FDM. Indeed, for the combination 1 (0°/90°), the structure presents an important stiffness and a high degree of stress distribution symmetry with respect to the notch. Moreover, the crack propagation is regular and straight, and the damage surfaces are on the same plane. However, for the combination 2 (-45°/45°), the structure is less resistant with an asymmetrical stress distribution according to two different planes. Research limitations/implications: In order to present an exhaustive study, we focused on the effect of two raster angles (including 0°/90°, -45°/45°) on the ABS crack propagation, additively manufactured. This study is still in progress for other raster angles, and will be developed from a design of experiments (DoE) design that incorporates all relevant factors. To highlight more the cracking mechanisms, microscopic observations will be developed in more depth. Practical implications: Our analysis can be used as a decision aid in the design of FDM parts. Indeed, we can choose the raster angle that would ensure the desired crack propagation resistance for a functional part. Originality/value: In this article, we have analyzed the mechanism of damage and crack propagation. This topic represents a new orientation for many research papers. For our study, we accompanied our experimental approach with an original numerical approach. In this numerical approach, we were able to mesh distinctly raster by raster for all layers.

Additive manufacturing techniques continue to develop and cover all industrial fields. However, the performances of aspect and mechanical behavior of the parts obtained by this process remain to be mastered and are still the subject of current research works. Among these performances, the one corresponding to the resistance to the propagation of cracks. In order to improve this very interesting property in various industrial fields, it is desirable to master the understanding of crack propagation in this type of structure obtained by 3D printing. The objective of this paper is to analyze and understand the effect of the adopted raster angle on the crack propagation in SENT specimens obtained by FDM in ABS (Acrylonitrile-Butadiene-Styrene). Two approaches were developed: one is experimental to determine the critical stress intensity factor KIC and the other is numerical to predict the possible paths of crack propagation.

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This research work aims to exhibit the possibility to topologically optimize a mesostructured part printed virtually by FDM taking into account the manufacturing parameters. The topology optimization of a 3D part printed by FDM was carried out using the software ABAQUS. On the other hand, a numerical approach using a script based on G-code file has been achieved to create a virtual model. Then, it was optimized according to the Solid Isotropic Material with Penalization (SIMP) method, which minimizing the strain energy was the objective function and the volume fraction of 30% was the constraint. The final topological optimization design of the virtual model is approximately similar to the homogeneous part. Furthermore, the strain energy of the virtual model is less than the homogeneous part. However, the virtually 3D optimized part volume is higher than the homogeneous one. In this study, we have limited our study on one layer owing to reduce the simulation time. Moreover, the time required to optimize the virtual model is inordinate. The ensuing study, we will optimize a multiple layer of the mesostructure. Our study provides a powerful method to optimize with accurately a mesostructure taken into consideration the manufacturing setting. In this paper, we have studied through an original approach the potential of topology optimization of a 3D part virtually printed by FDM. By means of our approach, we were able to optimize topologically the 3D parts printed by FDM taking into account the manufacturing parameters.

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