Investigation into the shear property of thin-walled additively manufactured structures using staggered fused filament fabrication

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Journal Article
Additive Manufacturing, 2020, 35
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© 2020 Additive manufacturing techniques, such as Fused Filament Fabrication (FFF), are rapidly revolutionising the manufacturing and mining sectors. This paper presents an investigation into the shear behaviour of thin-walled FFF structures, printed via a proposed ‘offset method’. Firstly, an alternative method of filament positioning in material extrusion is proposed, referred to as the ‘offset method’, which aims to reduce the volume of empty cavities between deposited material. Then the shear properties, density properties, and cross-sectional void surface area are compared to structures printed using the aligned printing method. Experimental results on solid printed (no infill) samples, through four different-sized nozzles, have shown the newly proposed method produces a 6.5 % increase in density and a 7.2 % improvement in maximum in-plane shear stress per millimetre increase in nozzle size, compared with the aligned method of FFF. The offset method was found to produce a material with increased interlayer contact, compared to the aligned method, which results in a higher fictitious shear stress modulus. The effect of the increased interlayer contact on the fictitious shear modulus and real shear stress was investigated using a FEM analysis of the unit cells. In short, using the same feedstock material, the offset method produces a stiffer material with a higher fictitious shear strength than the aligned method of FFF printing.
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