Micro-scale Representative Volume Element Research Articles

Multiscale image-based modeling for failure prediction of sheet molding compound composite under uniaxial tension

Carbon fiber reinforced polymer (CFRP) composites are extensively utilized as primary load-bearing components in various engineering applications due to their superior strength-to-weight ratio and excellent mechanical properties. However, their intricate microstructural interactions within composite present a significant challenge for failure analysis of CFRP. Although finite element (FE) simulations have been proven feasible to conduct the failure analysis, the classical FE models are developed based on homogeneous fiber characteristics, ignoring the influence of internal structures on the damage evolution process. This paper presents a multiscale image-based modeling approach to predict the tensile failure procedure of chopped carbon fiber sheet molding compound (SMC) composite. To accurately reconstruct the representative volume element (RVE) model of the SMC composite, synchrotron micro-X-ray computed tomography (μXCT) was adapted to explore the SMC internal microstructure. Then microscale RVE models with different fiber volume fractions were constructed to predict the corresponding microcosmic mechanical properties, which were used as the inputs for mesoscale RVE models to determine the constitutive parameters of fiber chips having varied fiber volume and orientations. Finally, the YOLOv5_Seg algorithm was employed to extract the geometric feature parameters of the fiber chips for mesoscale RVE modeling and then the failure location and sequence under uniaxial tension were predicted. It is found that the final simulated failure behaviors were consistent with the experimental observations, confirming the feasibility of this approach for understanding the failure mechanisms of CFRP composites. Thus, once the internal microstructure is determined using experimental techniques or predicted by simulating the composite manufacturing process, this approach can also be utilized for design optimization and performance evaluation for CFRP composites.

An ANN-based concurrent multiscale damage evolution model for hierarchical fiber-reinforced composites

In this paper, an ANN-based concurrent multiscale damage evolution model is proposed, which is able to investigate the complex failure behaviors of hierarchical fiber-reinforced composites. In the framework of the proposed model, yarn damage evolution laws at the mesoscale are indirectly derived from the microscale representative volume element (RVE), using artificial neural networks (ANNs) as a surrogate model. A homogenized characterization method is proposed to derive the homogenized damage variables. The homogenized strain and damage variables of the microscale RVE are taken as inputs and outputs in ANNs, respectively. The dataset is generated by combining clustering with the finite element simulation. A typical kind of plain-woven composite is adopted as a benchmark material for numerical implementation and experimental verification. The numerical predictions, including the tensile properties and damage evolution, are consistent with the results from quasi-static tension experiments.

Numerical Assessment of Effective Elastic Properties of Needled Carbon/Carbon Composites Based on a Multiscale Method

Needled carbon/carbon composites contain complex microstructures such as irregular pores, anisotropic pyrolytic carbon, and interphases between fibers and pyrolytic carbon matrices. Additionally, these composites have hierarchical structures including weftless plies, short-cut fiber plies, and needled regions. To predict the effective elastic properties of needled carbon/carbon composites, this paper proposes a novel sequential multiscale method. At the microscale, representative volume element (RVE) models are established based on the microstructures of the weftless ply, short-cut fiber ply, and needled region, respectively. In the microscale RVE model, a modified Voronoi tessellation method is developed to characterize anisotropic pyrolytic carbon matrices. At the macroscale, an RVE model containing hierarchical structures is developed to predict the effective elastic properties of needled carbon/carbon composites. For the data interaction between scales, the homogenization results of microscale models are used as inputs for the macroscale model. By comparing these against the experimental results, the proposed multiscale model is validated. Furthermore, the effect of porosity on the effective elastic properties of needled carbon/carbon composites is investigated based on the multiscale model. The results show that the effective elastic properties of needled carbon/carbon composites decrease with the increase in porosity, but the extent of decrease is different in different directions.

Sequential dual-scale approach for microstructure-informed ductile fracture prediction

This study presents a novel dual-scale finite element method to establish a microstructure-informed ductile fracture criterion for ferrite–martensite dual-phase (DP) steel. At the macroscale, an anisotropic plasticity model with rate-dependent hardening was employed to simulate the material's deformation history. Simultaneously, at the microscale, a dislocation density-based crystal plasticity model was utilized to simulate deformation within a representative volume element (RVE) of the dual-phase steel, constructed using tomography aided by a plasma-focused ion beam/electron backscatter diffraction system.The material properties of the ferrite and martensite phases were determined through X-ray diffraction (XRD) analysis and load-displacement measurements obtained via nanoindentation for each phase. The RVE simulation results were validated against experimentally measured mechanical properties and microstructural changes. The local deformation history at the fracture initiation site, extracted from the macroscale model, was used as boundary conditions for the microscale RVE simulation; sequential dual-scale approach. The models were applied to specimens with varying notch radii, generating different local stress triaxialities and accumulated shear strains at fracture onset. This process allowed the establishment of a ductile fracture criterion, which was further tested in a hole expansion experiment, demonstrating close alignment with experimental data.This sequential dual-scale analysis effectively predicts the deformation behavior of multiphase metallic materials by incorporating realistic microstructures while minimizing computational costs. Consequently, the proposed ductile fracture prediction technique offers a robust method with broad applicability across various metallic materials.

Prediction of the failure behavior of pseudo-ductile composites using a multi-scale finite element model

The hybridization technique has recently been used to produce a new generation of composites called pseudo-ductile composites, which have shown higher failure strain compared to conventional composites, minimizing the risks of the occurrence of a catastrophic failure. The pseudo-ductility behavior in these composites is obtained by hybridization of fibers with high and low failure strains. In this study, a multi-scale finite element (FE) model incorporating micro and macro-scales is proposed to predict the failure behavior of pseudo-ductile composites. A micro-scale representative volume element (RVE), consisting of randomly distributed fibers, was generated using a Python code. Periodic boundary conditions (PBCs) were applied to the RVE generated with a periodic geometry. To account for fiber failure and ply fragmentation, the tensile strength of fibers was distributed based on the Weibull distribution function and a user-defined UMAT subroutine was developed. Tensile loading was then applied to the RVE to simulate the composite’s mechanical behavior. For validation, an RVE was developed based on experimental data from recent research on thinply and conventional thickness composites. Numerical results were compared to experimental data, demonstrating acceptable agreement. In the final step, following a sequential multi-scale modeling approach, a macro-scale model was constructed based on the outputs of the micro-scale model subjected to tensile and shear loads. The results were compared with experimental data, revealing good agreement. The proposed model allows for the optimization of pseudo-ductile composite structures to achieve a desired set of mechanical properties without the need for conducting extensive experimental material tests.

Experimental and numerical study of the thermomechanical properties of flexible self-reinforced polyimide composite membrane

Polyimide membranes are favored in the aerospace field for their excellent comprehensive properties, but new application requirements demand higher strength, modulus and thermal expansion properties. Here, self-reinforced polyimide composite membranes (SRPICM) with varying fiber tow arrangement densities were fabricated by unidirectional reinforcement of polyimide fiber tows to enhance the thermomechanical properties of the membranes while maintaining the characteristics of low thickness and flexibility. A micro-scale representative volume element model with interface, and a macro-scale model containing cracks were developed based on the membranes' morphology to investigate the tensile and thermal expansion behavior of SRPICM. Experimental and numerical analyses demonstrated that fiber tows significantly improved the longitudinal tensile properties of SRPICM, with maximum increases in modulus and strength to 34.02 GPa and 1.26 GPa, respectively, over 13 times those of pure PI membranes. Further, the test results, combined with the two-scale finite element model revealed the evolution of longitudinal and transverse tensile deformation and thermal expansion behavior of SRPICM. The validity of the two-scale model was confirmed by experimental results, attributed to the practical consideration of interfacial bonding, prefabricated cracks and thermal residual stress effects during initial modeling. Notably, SRPICM with 10 fiber tows/20 mm arrangement density exhibited excellent longitudinal tensile properties (modulus and strength of 14.01 GPa and 470.89 MPa, respectively) and a longitudinal thermal expansion close to zero (0.03 μm/m°C), making it an ideal material for aerospace applications.

A scale-span method to characterize the mechanical property of BCF/PEEK considering uncertain structural characteristics

The focus of this study is exploring a scale-span characterization method to predict the mechanical properties of Braided Carbon Fiber Reinforced Poly Ether Ether Ketone (BCF/PEEK) considering structural uncertainty. Firstly, a complicated micro-scale Representative Volume Element (RVE) model that considers the random position and size of fiber was established via the developed Python script. Analogously, a mathematical expression adopted by the trust region algorithm was proposed to accurately describe the detailed cross-sectional shapes and fluctuation amplitude characteristics of BCF/PEEK for the sake of establishing the precision meso-scale RVE model. Then, the corresponding elastic properties that consider fiber volume fraction and fiber distribution location were characterized via the span-scale characterization method. Meanwhile, the influence of fiber bundle fluctuation amplitude and fiber volume fraction on the mechanical properties was investigated as well. In addition, the mechanical properties of BCF/PEEK with the change of the braid angle between warp and weft yarn were predicted via the established meso-scale RVE model. Finally, a series of experiments have been carried out. The maximum and minimum absolute prediction deviation of all elastic property parameters were only 4.07 % and 1.41 %, respectively, which verified the proposed scale-span characterization method can predict the mechanical properties of composites well.

Multiscale damage and low-velocity impact study of three-dimensional woven composites

Three-dimensional woven composites address the limitation of weak interlaminar strength found in traditional laminated composites and offer superior resistance to out-of-plane impact. However, the complex material composition and structural intricacies necessitate investigation into their damage mechanisms. This study introduces novel and reliable microscale and mesoscale Representative Volume Element (RVE) models for three-dimensional woven composites, developed through advanced CT scanning and comprehensive multi-directional tensile and shear experiments. The research explores the impact of fiber volume fraction on yarn mechanical properties using the microscale RVE model, yielding precise macroscale homogenization parameters through the mesoscale RVE model. Furthermore, a macro-meso model tailored for low-velocity impact scenarios is established, significantly enhancing computational efficiency without compromising accuracy, thus providing support for further research on the impact properties of three-dimensional woven composites.

The Influence of the Interface on the Micromechanical Behavior of Unidirectional Fiber-Reinforced Ceramic Matrix Composites: An Analysis Based on the Periodic Symmetric Boundary Conditions

The long-term periodicity and uncontrollable interface properties during the preparation process for silicon carbide fiber reinforced silicon carbide-based composites (SiCf/SiC CMC) make it difficult to thoroughly investigate their mechanical damage behavior under complex loading conditions. To delve deeper into the influence of the interface strength and toughness on the mechanical response of microscopic representative volume element (RVE) models under complex loading conditions, in this work, based on numerical simulation methods, a microscale representative volume element (RVE) with periodic symmetric boundary conditions for the material is constructed. The phase-field fracture theory and cohesive zone model are coupled to capture the brittle cracking of the matrix and the debonding behavior at the fiber/matrix interface. Simulation analysis is conducted for tensile, compressive, and shear loading as well as combined loading, and the validity of the model is verified based on the Chamis theory. Further investigation is conducted into the mechanical response behavior of the microscale RVE model under complex loading conditions in relation to the interface strength and interface toughness. The results indicate that under uniaxial loading, increasing the interface strength leads to a tighter bond between the fiber and matrix, suppressing crack initiation and propagation, and significantly increasing the material’s fracture strength. However, compared to the transverse compressive strength, increasing the interface strength does not continuously enhance the strength under other loading conditions. Meanwhile, under the condition of strong interface strength of 400 MPa, an increase in the interface toughness significantly increases the transverse compressive strength of the material. When it increases from 2 J/m2 to 20 J/m2, the transverse compressive strength increases by 28.49%. Under biaxial combined loading, increasing the interface strength significantly widens the failure envelope space under σ2-τ23 combined loading; with the transition from transverse compressive stress to tensile stress, the transverse shear strength shows a trend of first increasing and then decreasing, and when the ratio of transverse shear displacement to transverse tensile/compressive displacement is −1, it reaches the maximum. This study provides strong numerical support for the investigation of the interface properties and mechanical behavior of SiCf/SiC composites under complex loading conditions, offering important references for engineering design and material performance optimization.

Investigation of Macroscopic Mechanical Behavior of Magnetorheological Elastomers under Shear Deformation Using Microscale Representative Volume Element Approach.

Magnetorheological elastomers (MREs) are a class of smart materials with rubber-like qualities, demonstrating revertible magnetic field-dependent viscoelastic properties, which makes them an ideal candidate for development of the next generation of adaptive vibration absorbers. This research study aims at the development of a finite element model using microscale representative volume element (RVE) approach to predict the field-dependent shear behavior of MREs. MREs with different elastomeric matrices, including silicone rubber Ecoflex 30 and Ecoflex 50, and carbonyl iron particles (CIPs) have been considered as magnetic particles. The stress-strain characteristic of the pure silicon rubbers was evaluated experimentally to formulate the nonlinear Ogden strain energy function to describe hyper-elastic behavior of the rubbery matrix. The obtained mechanical and magnetic properties of the matrix and inclusions were integrated into COMSOL Multiphysics to develop the RVE for the MREs, in 2D and 3D configurations, with CIP volume fraction varying from 5% to 40%. Periodic boundary condition (PBC) was imposed on the RVE boundaries, while undergoing shear deformation subjected to magnetic flux densities of 0-0.4 T. Comparing the results from 2D and 3D modeling of isotropic MRE-RVE with the experimental results from the literature suggests that the 3D MRE-RVE can be effectively used to accurately predict the influence of varying factors including matrix type, volume fraction of magnetic particles, and applied magnetic field on the mechanical behavior of MREs.

Data-physics driven multiscale approach for high-pressure resin transfer molding (HP-RTM)

We present a multiscale computational framework for high-pressure resin transfer molding of fiber-reinforced composites. Due to the relatively rapid speed of resin flow and the significant convective effects, this process is governed by the nonlinear steady-state Navier–Stokes equations, as opposed to the linear Stokes equations commonly adopted for the simulation of classical resin transfer molding processes. To overcome the computational challenge of directly solving the high-pressure resin filling problem through the fiber preform, we developed a data-driven nonlinear homogenization approach where the average velocity and instantaneous permeability computed from the microscale representative volume element problem provide solution-dependent coefficients for the macroscale problem. The proposed data-physics driven computational framework has been validated against the direct numerical solution of the steady-state Navier–Stokes equations.

Numerical simulation and experimental validation of ratchetting deformation of short fiber-reinforced polymer composites

This paper proposes a micromechanical model based on the finite element method (FEM) to analyze the ratchetting deformation of short glass fiber-reinforced polymer composites (SFRPCs). To reasonably consider the complex mechanical characteristics of the polymeric matrix under asymmetrical stress-controlled cyclic loading, a damage-coupled nonlinear viscoelastic-viscoplastic (VE-VP) cyclic constitutive model was constructed. The cyclic constitutive model of the matrix was introduced into the FEM model utilizing a user-defined material, and the corresponding experimental validation of the matrix was conducted. Subsequently, the cyclic constitutive model was introduced into the analysis of the micro-FEM model of the composites. The random orientation was considered to generate fibers in the FEM. Based on the analysis of the microscale representative volume element (RVE) model, the effects of different fiber content and cyclic peak stress on the ratchetting of SFRPCs were studied in detail. After validation, the effects of the fiber length and fiber stiffness on the ratchetting deformation of SFRPCs are discussed based on the developed micro-FEM model. The results show that the increase in the fiber length and fiber stiffness reduced the ratchetting deformation of SFRPCs within a specific content range. The model can assess the ratchetting deformation and damage evolution within the composites to provide more accurate predictions of the ratchetting deformation of SFRPCs and guide the expanded application of SFRPCs in structures.

Voids effect on micromechanical response of elastoplastic fiber-reinforced polymer composites using 1D higher-order theories

This work investigates the effect of voids within the matrix of composite materials. Effects on local stress and plastic strain values are evaluated by conducting a micromechanical analysis. The microscale Representative Volume Element (RVE) is modeled through refined 1D elements based on the Carrera Unified Formulation (CUF). Using 1D models for the RVE leads to a significant reduction in computational costs compared to standard 3D elements. Fibers are modeled as orthotropic, and the matrix has an elastoplastic behavior. Random distributions of voids are considered, and statistical analyses are carried out. Furthermore, the influence of the depth of the RVE is investigated. The results show significant mean and peak stress values increases as the void volume fraction grows. Also, the use of deeper RVE leads to higher stress values.

Research into the thermal expansion behavior of spread tow woven pierced carbon/carbon composites at high temperature

Textile-reinforced carbon/carbon composites are frequently used for thermal safety due to their superb thermophysical properties. The coefficient of thermal expansion (CTE) is a fundamental performance metric of spread tow woven pierced carbon/carbon composites (STWPs). The multiscale representative volume element (RVE) models constructed as part of this work were used for investigating the CTEs of STWPs at high temperature. The temperature displacement coupling analysis step was established to predict the CTEs of STWPs considering the high-temperature environment. In addition, periodic displacement boundary conditions were adopted as node constraints with the spatial periodicity of RVE models. The influences of pore positions and configurations on the CTEs of the matrix were considered through two different matrix RVE model. The CTEs of the spread tow (ST) and fiber rod were computed using two microscale RVE models with an unequal fiber volume fraction. A novel modeling strategy for the mesoscale RVE model was put forth in order to calculate the CTEs of the STWPs due to the remarkable lightness and thinness of the ST. Only 9.64% and 7.92% errors in the in-plane and out-of-plane directions were found when the experimental findings were compared to those predicted by numerical models, demonstrating the accuracy and effectiveness of the multiscale RVE models. Moreover, the impacts of areal density of ST woven fabric on the CTEs of STWPs were discussed. The fundings demonstrated that the in-plane and out-of-plane CTEs both decreased as the areal density increased.

Multiscale Analysis of the Highly Stretchable Carbon−Based Polymer Strain Sensor

In this paper, a multiscale analysis method was proposed to simulate carbon nanoparticles (CNPs)-filled polymers which can be strain sensors applied in wearable electronic devices, flexible skin, and health monitoring fields. On the basis of the microstructure characteristics of the composite, a microscale representative volume element model of the CNPs-filled polymer was established using the improved nearest-neighbor algorithm. By finite element analysis, the variation of the junction widths of adjacent aggregates can be extracted from the simulation results. Then, according to the conductive mechanism of CNP-filled polymers, the composite was simplified as a circuit network composed of vast random resistors which were determined by the junction widths between adjacent aggregates. Hence, by taking junction widths as the link, the resistance variation of the CNPs-filled polymer with the strain can be obtained. To verify the proposed method, the electromechanical responses of silicone elastomer filled with different CNPs under different filling amounts were investigated numerically and experimentally, respectively, and the results were in good agreement. Therefore, the multiscale analysis method can not only reveal the strain-sensing mechanism of the composite from the microscale, but also effectively predict the electromechanical behavior of the CNPs-filled polymer with different material parameters.

Elastoplastic analysis of AA7075-O aluminum sheet by hybrid micro-scale representative volume element modeling with really-distributed particles and in-situ SEM experimental testing

• Presents a novel computationally-efficient reconstruction of 3D RVE model of second-phase particle-strengthened AA7075-O sheet with real distribution of particles based on FIB-SEM techniques. • Three types of second-phase particles (i.e., irregularly-shaped iron-rich particle Al 3 Fe, elliptically-shaped particle MgZn 2 , and needle-like particle CuAl 2 ) are determined using SEM-based EDS and EBSD techniques. • Presents a systematic study of the overall elastic-plastic response by developing and applying a hybrid experimental analysis and computational modeling framework. • Good agreement is observed in the comparison of RVE results with that of in-situ SEM tensile tests, indicating that the real 3D microstructure-based RVE models can accurately predict the plastic deformation and interfacial failure evolution in AA7075-O sheet. This paper addresses the challenge of reconstructing randomly distributed second-phase particle-strengthened microstructure of AA7075-O aluminum sheet material for computational analysis. The particle characteristics in 3D space were obtained from focused ion beam and scanning electron microscopy (FIB-SEM) and SEM-based Electron Backscatter Diffraction/Energy Dispersive X-ray Spectrometry (EBSD/EDS) techniques. A theoretical framework for analysis of elastic-plastic deformation of such 3D microstructures is developed. Slip-induced shear band formation, void initiation, growth and linkage at large plastic strains during uniaxial tensile loading were investigated based on reconstructed 3D representative volume element (RVE) models with real-distribution of particles and the results compared with experimental observations. In-situ SEM interrupted tension tests along transverse direction (TD) and rolling direction (RD), employing microscopic-digital image correlation (μ-DIC) technique, were carried out to investigate slip bands, micro-voids formation and obtain microstructural strain maps. The resulting local strain maps were analyzed in relation to the experimentally observed plastic flow localization, failure modes and local stress maps from simulations of RVE models. The influences of particle size, shape, orientation, volume fraction as well as matrix-particle interface properties on local plastic deformation, global stress-strain/strain-hardening curves and interfacial failure mechanisms were studied based on 3D RVE models. When possible, the model results were compared with in-situ tensile test data. In general, good agreement was observed, indicating that the real 3D microstructure-based RVE models can accurately predict the plastic deformation and interfacial failure evolution in AA7075-O aluminum sheet.

Numerical Tensile Damage Procedure Analysis of Angle-Ply Laminate Using Multi-Scale RVEs with Smear Crack Models.

This paper reported the tensile failure strengths and damage procedure of composite laminate manufactured from the toughened-epoxy T800 prepreg at multi-scale levels. According to the exterior and interior distinction of each layer in laminate, the macro/mesoscale representative volume element (macro-RVE, meso-RVE) was first constructed, respectively. Then the micro-scale representative volume element (micro-RVE) with a hexagonal fiber-packed pattern in the interior zone of each layer in the laminate was finally determined on the principle of the same fiber volume fraction between the composite laminate and multi-scale RVEs. In the multi-RVEs analysis, the mechanical failure strengths of each scale model were transmitted from the last-scale model’s homogenization, such as the meso-RVE from micro-RVE and the macro-RVE from meso-RVE. Based on our previous report, the innovative multi-scale damage and post-damage models on the concept of the smear crack were improved fully and incorporated by user-defined material subroutines (UMATs), such as in the addition of multiple cracks co-coupled, which makes it predict the element damage procedure. The averaged mechanical responses with damage mechanism of multi-scale RVEs under tensile, compressive, or shear loadings were obtained wholly by the homogenization method. The macroscale tensile damage initiation and propagation procedure were analyzed in detail including their global/local responses, being extended to comparison with experimental results.

Analysis of nonlinear shear and damage behaviour of angle-ply laminates with Direct FE2

In this paper, non-linear shear and damage behaviour of angled ply laminates is studied and simulated with the Direct FE2 approach. The FE2 method allows dual scale modelling of composite laminates by coupling micromechanical models of Representative Volume Element (RVE) of unidirectional fibre reinforced polymer composite with a macroscale laminate level model. Angled ply laminates under uniaxial tension are chosen because their non-linear behaviour arises from matrix plasticity and fibre reorientation under tension in addition to constituent damage and becomes important particularly for large deformation. This requires additional effort to account for fibre rotation to existing homogenized ply damage models. The FE2 approach requires only constituent (matrix and reinforcement) properties as input, thus removing the need for homogenized laminate and ply-level constitutive properties. At the macroscale, the FE2 model gave good prediction of experimental stress-strain response of laminates under uniaxial tension, while concurrently, the microscale RVEs captured fibre rotation, micro-cracks and fibre rupture.

Multi-scale Modeling of Polymeric Composites Including Nanoporous Fillers of Milled Anodic Alumina

A polymer composite based on an innovative filler consisting of microscale powder of nanoporous alumina is modeled. The passing-through nanoscale pores in this system—roughly columnar cylindrical, with diameter of the order of 100 nm—are fully penetrated by the resin, which is not bonded to the inner pore walls by any chemical agent. This system, previously assessed by laboratory experiments, is modeled here for the first time, based on a computational multi-scale hierarchical approach. First, microscale representative volume element (RVE) is modeled in two steps using finite element modeling. Then, the macro-scale RVE is characterized, using a combination of micromechanical rules. The elastic response of the composite is simulated to predict its Young’s modulus. This simulation confirms the former experimental results and helps to shed light on the response of the investigated material, which may represent a novel system for use in disparate composite applications. In particular, the nanoporous microfillers composite is compared with a composite material containing the fillers of the same material yet nonporous, bonded to the matrix. It appears that, with respect to this standard concept of three-phase composites, the presence of the nanopores can compensate for the absence of the bonding agent.

Longitudinal compression failure of 3D printed continuous carbon fiber reinforced composites: An experimental and computational study

Fused filament fabrication (FFF) with continuous carbon fiber filaments has proven to be a promising manufacturing technique in engineering applications. To provide guidance in the design of 3D printed carbon fiber reinforced polymer (CFPR) components, the longitudinal compression failure of continuous CFPR composites using the FFF technique is investigated systematically. First, longitudinal compression tests are performed for 3D printed continuous CFRP composites with and without designed waved filaments. The degradation of the failure strength is remarkable when the waved filaments are introduced. Nevertheless, further degradation is limited when more waved filaments are adopted. Next, the fracture morphologies are analyzed, and in-plane and out-of-plane kink-bands are observed in the microscopic images. For the specimens with waved filaments, fracture occurs at the cross-section with the contact region of the waved and regular filaments, as well as the cross-section with the maximum misalignment angle. Correspondingly, a computational framework for 3D printed continuous CFPR composites is established to explore the longitudinal compression failure mechanisms. The meso-scale computational models are reconstructed according to the geometric features of the deposited continuous CFRP filaments and the actual void volume fraction. The elastic properties of the filament are calculated by a micro-scale representative volume element (RVE) model, which is based on the fiber random distribution algorithm. The plastic deformation and failure is described by a filament constitutive model which is established by the Liu-Huang-Stout yield criterion and a simplified Tsai-Wu failure criterion. The experimental validation demonstrates the feasibility of the computational models to predict the stress-strain curves of 3D printed materials, and also capture the realistic longitudinal compression failure behavior.