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<p>Recent advancements in additive manufacturing have enabled fabrication of hybrid structures through combination of dissimilar materials with controlled spatial distribution. In this study, an innovative structure consisting of alternating layers of polylactic acid (PLA) and carbon fiber-reinforced PLA (Carbon-PLA) was fabricated using fused deposition modeling and evaluated under open-hole tensile (OHT) loading. The objective was to investigate the stress concentration behavior and mechanical response of the layered configuration in comparison with its constituent materials. Experimental results indicate that multi-material structure exhibited an ultimate tensile strength of 26.66&#xa0;MPa<i>,</i> elongation of 2.78%, demonstrating intermediate behavior between PLA (25&#xa0;MPa) and Carbon-PLA (36.63&#xa0;MPa). Finite element simulations were employed to analyze stress distribution around open-hole region and to provide a comparative assessment of mechanical response. The results confirm that stress concentration is predominantly governed by specimen geometry, while material stiffness influences stress magnitude and failure behavior. The study provides insight into mechanical performance of layered dual-material FDM structures under stress concentration conditions. Findings highlight potential of such configurations for lightweight, low-load applications where tailored stiffness and manufacturability are of interest.</p>

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Finite Element Simulation of Innovative Open-Hole Tensile Test Specimen Fabricated through Additive Manufacturing

  • 期刊论文

  • 发表日期：

    2026年7月29日

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  • Dhinakaran Veeman,
  • Gunal Palani,
  • Pechimuthu Arumugaperumal,
  • Mohan Kumar Subramaniyan

摘要

Recent advancements in additive manufacturing have enabled fabrication of hybrid structures through combination of dissimilar materials with controlled spatial distribution. In this study, an innovative structure consisting of alternating layers of polylactic acid (PLA) and carbon fiber-reinforced PLA (Carbon-PLA) was fabricated using fused deposition modeling and evaluated under open-hole tensile (OHT) loading. The objective was to investigate the stress concentration behavior and mechanical response of the layered configuration in comparison with its constituent materials. Experimental results indicate that multi-material structure exhibited an ultimate tensile strength of 26.66 MPa, elongation of 2.78%, demonstrating intermediate behavior between PLA (25 MPa) and Carbon-PLA (36.63 MPa). Finite element simulations were employed to analyze stress distribution around open-hole region and to provide a comparative assessment of mechanical response. The results confirm that stress concentration is predominantly governed by specimen geometry, while material stiffness influences stress magnitude and failure behavior. The study provides insight into mechanical performance of layered dual-material FDM structures under stress concentration conditions. Findings highlight potential of such configurations for lightweight, low-load applications where tailored stiffness and manufacturability are of interest.