A multiscale analysis approach to predict mechanical properties in fused deposition modeling parts

Additive manufacturing has evolved from a rapid prototyping tool to a set of manufacturing processes for functional parts. One of their most outstanding features is the ability to build complex geometry parts. However, their industrial application is limited because these parts exhibit heterogeneous and porous micro/mesostructures with anisotropic behavior. These structural characteristics, mainly porosity, are strongly related to the building parameters. In this work, a computational multiscale homogenization approach was implemented to determine the mechanical properties of unidirectional and criss-cross mesostructures generated by a material extrusion process (MEP). Representative volume elements (RVE) for simplified and real-like pore geometries were created to model the mesostructures and to perform the multiscale analysis. Stiffness tensor for each RVE was obtained and graphically represented to observe the mechanical properties as a function of the orientation. A great influence of the pore geometry on mechanical properties was observed. Finally, by comparing with experimental data, the results obtained were validated.