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Fused deposition modelling (FDM) technology was investigated in order to produce a part designed to support a test load without permanent deformation.  A topology optimization script was developed in order to define the final shape of the part. The solver used for the numerical analysis is LS-Dyna (implicit formulation). The algorithm follows the element removal based on the stress state and it can be very simply implemented. This solution of developing a custom code was adopted because plastic strain state was monitored and this is not yet implemented in other topology optimization applications. The results of the traction test were assembled and investigated in order to outline some of the typical parameters used for mechanical characterization. As a general overview of the results it was found that the parts manufactured using a 45°/45° stacking configuration are stronger that the ones manufactured using 0°/90° stacking configuration.

Fused deposition modeling; mechanical properties; part optimization