Testing the Mechanical Response of Additively Manufactured Composite Joints

Abstract

This paper aims to assess the quality of composite joints made with the Fused Filament Fabrication (FFF) additive manufacturing technique through strength tests. The first part of this paper details the design of different test sample versions with standardised geometry and the methods of joining plastics by application of 3D printing. The details cover the test apparatus used in the research, sample preparation methodology, as well as tensile and impact testing methodology. The test sample versions were selected according to the test types to have the results fully reproduce the mechanical response of the composite materials to the input forces. The second part of this paper analysis of the test results, presenting the fabrication accuracy of the test samples and their mechanical response recorded during the tests. Five test specimens of each version were produced to enable statistical analysis of the test results, which was indispensable for a reliable data analysis. The tests made it possible to determine how the proposed joints of plastic materials responded to the input forces, the maximum transmitted force limit, and the flaws of each version’s design. The test results made it possible to adapt the suggested solutions in the design engineering of programmable energy-absorbing structures.