Investigating Mechanical Characterization and Failure Analysis of 3D-Printed Multilayer Composite Beams by Experimental Testing and FE Modeling

This study focuses on the experimental investigation of multilayered composite beams fabricated using 3D printing technology to enhance their mechanical performance for modern applications. These components are crucial in aerospace, automotive, and civil engineering industries. Through employing fiber-reinforced outer layers and optimized internal core structures, this research explores how 3D printing can provide tailored mechanical properties that overcome the capabilities of traditional manufacturing techniques. The core of this study is an experimental approach combined with FEM to assess the structural behavior, mechanical properties, and failure modes of these 3D-printed multilayer beams. The experimental results reveal that adjusting print parameters, such as infill patterns, layer orientations, and printing speeds, can significantly impact stiffness, flexibility, and energy absorption. FEM simulations validate the experimental data, accurately predicting stress distribution, deflection behavior, and failure points under various loading conditions. The main challenges in the 3D printing process, such as anisotropy, layer adhesion, print quality, and material inconsistencies, are addressed to understand their impact on the structural integrity of the beams. Issues like defects, dimensional inaccuracies, and filament variability are examined to optimize print settings for improved performance. This study highlights the potential of 3D-printed multilayer composites to deliver high-performance solutions tailored to demanding applications where lightweight and robust materials are essential. The findings provide actionable understandings for overcoming common 3D printing limitations, contributing to the efficient production of reliable and durable components for industry use.