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<p>Multi-material additive manufacturing is pushing the boundaries of research and enabling the creation of innovative objects with customized properties. However, certain critical aspects remain insufficiently investigated; specifically, the mechanical strength and integrity of interfaces between dissimilar materials. This study aims to investigate and quantitatively characterize these interfaces through a combination of experimental testing and numerical modeling. First, the mechanical properties of the materials are assessed following standardized protocols. Then, interfacial strength is evaluated through experimental tests under different loading conditions. To better understand and predict the behavior of these interfaces, finite element method models are developed and validated against experimental results. This work provides a methodological approach that can be applied in the design of products specifically intended for end-of-life disassembly&#xa0;and in the optimization of interfacial geometries to improve adhesion strength. This structured approach contributes to enhancing the reliability and performance of multi-material structures. The developed finite element method (FEM) models exhibit a maximum deviation of 15% from experimental results in most cases, thereby validating the proposed approach for accurately predicting interfacial behavior and quantitatively assessing the load-bearing capacity of multi-material additive-manufactured components.</p>

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Cohesive zone modeling to predict multi-material additive manufacturing interfaces behavior

  • 期刊论文

  • 发表日期：

    2025年6月29日

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  • Matilde Minuto,
  • Mattia Frascio

摘要

Multi-material additive manufacturing is pushing the boundaries of research and enabling the creation of innovative objects with customized properties. However, certain critical aspects remain insufficiently investigated; specifically, the mechanical strength and integrity of interfaces between dissimilar materials. This study aims to investigate and quantitatively characterize these interfaces through a combination of experimental testing and numerical modeling. First, the mechanical properties of the materials are assessed following standardized protocols. Then, interfacial strength is evaluated through experimental tests under different loading conditions. To better understand and predict the behavior of these interfaces, finite element method models are developed and validated against experimental results. This work provides a methodological approach that can be applied in the design of products specifically intended for end-of-life disassembly and in the optimization of interfacial geometries to improve adhesion strength. This structured approach contributes to enhancing the reliability and performance of multi-material structures. The developed finite element method (FEM) models exhibit a maximum deviation of 15% from experimental results in most cases, thereby validating the proposed approach for accurately predicting interfacial behavior and quantitatively assessing the load-bearing capacity of multi-material additive-manufactured components.