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<p>The mechanical performance of joints between rigid and flexible materials significantly impacts the engineering applications of multi-material structures, though the effects of joint types and parameters remain uncertain. This study explores the tensile and shear behaviors of alternate deposition and mechanical interlocking joints in FDM-fabricated PLA/TPU (PT) and PLA/Soft PLA (PSP) systems, focusing on key geometric parameters such as deposition width (<i>D</i>) and interlock depth/angle (<i>h</i>/<i>θ</i>). Findings reveal that joint performance is highly influenced by the flexible filament’s properties and material compatibility. In mechanical interlocking joints, the PT system exhibits superior tensile strength at a depth of 2&#xa0;mm, with maximum values of 6.58 ± 0.33&#xa0;MPa for PT and 5.91 ± 0.25&#xa0;MPa for PSP, both at a 45° angle. Maximum shear strength occurs at a 22.5° angle and 4&#xa0;mm depth, with PT at 24.47 ± 1.99&#xa0;MPa and PSP at 18.12 ± 0.85&#xa0;MPa. In alternate deposition joints, tensile strengths increase with <i>D</i>, plateauing at 7.42 ± 0.33&#xa0;MPa for PT (<i>D</i> ≥ 6&#xa0;mm) and 5.29 ± 0.01&#xa0;MPa for PSP (<i>D</i> ≥ 4&#xa0;mm). The PT system demonstrates a 12.77% higher tensile strength in alternate deposition compared to mechanical interlocking joints, while PSP exhibits 11.72% higher tensile strength in mechanical interlocking joints. These insights offer guidance for selecting joint types and parameters in multi-material applications, advancing the engineering of metamaterials and flexible devices.</p>

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Mechanical performance of bi-material FDM rigid–flexible joints: effects of alternate deposition and mechanical interlocking

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2026年3月29日

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  • Chi Zhang,
  • Yinchuan He,
  • Kan Wang,
  • Kwong Ming Tse,
  • Tingting Wang

摘要

The mechanical performance of joints between rigid and flexible materials significantly impacts the engineering applications of multi-material structures, though the effects of joint types and parameters remain uncertain. This study explores the tensile and shear behaviors of alternate deposition and mechanical interlocking joints in FDM-fabricated PLA/TPU (PT) and PLA/Soft PLA (PSP) systems, focusing on key geometric parameters such as deposition width (D) and interlock depth/angle (h/θ). Findings reveal that joint performance is highly influenced by the flexible filament’s properties and material compatibility. In mechanical interlocking joints, the PT system exhibits superior tensile strength at a depth of 2 mm, with maximum values of 6.58 ± 0.33 MPa for PT and 5.91 ± 0.25 MPa for PSP, both at a 45° angle. Maximum shear strength occurs at a 22.5° angle and 4 mm depth, with PT at 24.47 ± 1.99 MPa and PSP at 18.12 ± 0.85 MPa. In alternate deposition joints, tensile strengths increase with D, plateauing at 7.42 ± 0.33 MPa for PT (D ≥ 6 mm) and 5.29 ± 0.01 MPa for PSP (D ≥ 4 mm). The PT system demonstrates a 12.77% higher tensile strength in alternate deposition compared to mechanical interlocking joints, while PSP exhibits 11.72% higher tensile strength in mechanical interlocking joints. These insights offer guidance for selecting joint types and parameters in multi-material applications, advancing the engineering of metamaterials and flexible devices.