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<p>The shift of additive manufacturing from pure prototyping technology to producing end-use components has raised a new challenge for mechanical design. Efficient design requires a method for predicting the strength of a fused filament fabricated (FFF) material to replace slow and costly trial and error methods. Previous studies have developed models for failure prediction in FFF materials but often only for in-plane stress analysis, not for full 3D. In the current paper, a modified Tsai-Wu (TW) criterion for full 3D failure prediction of FFF poly-ethylene terephthalate glycol (PETG) polymer was implemented both analytically and numerically. Baseline experiments were conducted to determine the Tsai-Wu coefficients. Using the determined coefficients and known stress state, the criterion was solved analytically to predict the yield strength for given scenarios. The same approach was followed numerically using ANSYS ACP-Pre and Mechanical to simulate the aforementioned scenarios. Both methods showed promise in predicting the yield stress, with the ANSYS approach consistently showing higher precision. Verification experiments were then performed both in tension and compression to provide real-world data against analytically and numerically predicted yield strengths. The proposed methods were effective in predicting the yield strength of FFF material for both tensile and compressive loads, factoring in the full 3D orientation between the printed strands and applied forces.</p>

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Enhancing yield prediction of FFF materials with modified Tsai–Wu failure criterion

  • 期刊论文

  • 发表日期：

    2025年11月6日

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  • Tim Clarke,
  • Ali Hosseini

摘要

The shift of additive manufacturing from pure prototyping technology to producing end-use components has raised a new challenge for mechanical design. Efficient design requires a method for predicting the strength of a fused filament fabricated (FFF) material to replace slow and costly trial and error methods. Previous studies have developed models for failure prediction in FFF materials but often only for in-plane stress analysis, not for full 3D. In the current paper, a modified Tsai-Wu (TW) criterion for full 3D failure prediction of FFF poly-ethylene terephthalate glycol (PETG) polymer was implemented both analytically and numerically. Baseline experiments were conducted to determine the Tsai-Wu coefficients. Using the determined coefficients and known stress state, the criterion was solved analytically to predict the yield strength for given scenarios. The same approach was followed numerically using ANSYS ACP-Pre and Mechanical to simulate the aforementioned scenarios. Both methods showed promise in predicting the yield stress, with the ANSYS approach consistently showing higher precision. Verification experiments were then performed both in tension and compression to provide real-world data against analytically and numerically predicted yield strengths. The proposed methods were effective in predicting the yield strength of FFF material for both tensile and compressive loads, factoring in the full 3D orientation between the printed strands and applied forces.