Finite Element Analysis to determine the impact of Infill density on Mechanical Properties of 3D Printed Materials

Additive manufacturing (AM) is the process in which objects are created through the layer-by-layer deposition of material that is controlled by a computer. The infill is the internal structure of the 3D printed model. It determines the strength, weight, cost, time, and overall quality of the part. Ranging from simple lines to more complex geometric shapes, infill patterns can affect a part's performance. This study aims to conduct a Numerical Analysis for cross pattern infills with various infill densities of 0%, 10%, 19, 28%, 64%, and 100%. CAD models were developed, and FEA Analysis was performed to compare the deformation and Von Mises stresses produced by a cuboid structure under 1 MPa compressional load. Linear Isotropic Material with Young's Modulus of 70 GPA and the Poisson ratio of 0.3 was used, and quarter symmetry was applied to reduce the mesh size. The results revealed that the increasing infill percentage decreases the deformation and Von Mises stresses produced in a body under compression loading. This study helps to determine optimal infill density for maximizing strength and minimizing the weight of the 3D printed part.