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<p>This study investigates the failure behavior of 3D-printed polylactic acid (PLA) by integrating fracture mechanics and degradation modeling, through a combination of experimental testing and predictive modelling. Eighteen single edge notched tensile (SENT) specimens, featuring pre-crack lengths of 0–10 mm and oriented at 0°, 45°, and 90° relative to filament deposition, were tested to evaluate crack propagation. In parallel, a progressive degradation via layer removal (thickness reduction) method was applied to 10 ASTM D638 Type V specimens, with incremental 0.2 mm thickness reductions via 3D printing to simulate material degradation. Damage progression was quantified using energy-based and stress-based models. The results demonstrated that crack orientation and size significantly affect tensile strength, with the energy-based model outperforming in predicting failures in SENT specimens, while the stress-based model excelled at capturing stress redistribution during layer reduction. Notably, critical life fractions indicating the onset of rapid failure ranged from 0.07 to 0.27 for pre-crack augmentation, compared to 0.4 to 0.43 for layer removal, underscoring pre-crack augmentation as a more severe defect, particularly at 0° orientation due to stress concentration at the crack tip. These insights link fracture mechanics to degradation simulation, providing valuable guidance for improving durability predictions and optimizing 3D-printed PLA designs for engineering applications.</p>

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Damage evolution and fracture behavior in 3D-printed materials: effects of crack propagation and progressive layer degradation

  • 期刊论文

  • 发表日期：

    2026年1月14日

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  • Taoufik Hachimi,
  • Fouad Ait Hmazi,
  • Fatima Ezzahra Arhouni,
  • Najat Zekriti,
  • Hicham Doghmi,
  • Fatima Majid

摘要

This study investigates the failure behavior of 3D-printed polylactic acid (PLA) by integrating fracture mechanics and degradation modeling, through a combination of experimental testing and predictive modelling. Eighteen single edge notched tensile (SENT) specimens, featuring pre-crack lengths of 0–10 mm and oriented at 0°, 45°, and 90° relative to filament deposition, were tested to evaluate crack propagation. In parallel, a progressive degradation via layer removal (thickness reduction) method was applied to 10 ASTM D638 Type V specimens, with incremental 0.2 mm thickness reductions via 3D printing to simulate material degradation. Damage progression was quantified using energy-based and stress-based models. The results demonstrated that crack orientation and size significantly affect tensile strength, with the energy-based model outperforming in predicting failures in SENT specimens, while the stress-based model excelled at capturing stress redistribution during layer reduction. Notably, critical life fractions indicating the onset of rapid failure ranged from 0.07 to 0.27 for pre-crack augmentation, compared to 0.4 to 0.43 for layer removal, underscoring pre-crack augmentation as a more severe defect, particularly at 0° orientation due to stress concentration at the crack tip. These insights link fracture mechanics to degradation simulation, providing valuable guidance for improving durability predictions and optimizing 3D-printed PLA designs for engineering applications.