Estimation and validation of elastic constants in fused filament fabrication 3D printing: From mesoscale to macroscale

• Analysis of deposition geometry of fused filament fabrication. • Realistic estimation of elastic constants and validation: FEM vs experimental. • Application to complex stress state case and validation with DIC. • Elastic constants ready to use for numerical modelling via FEM. Evaluating the mechanical properties of 3D-printed parts is a cumbersome task. This study poses an approach based on computational homogenization to estimate the elastic constants of fused filament fabrication 3D-printed parts. A whole methodology for characterization and experimental validation is necessary to improve finite element numerical models. Samples are characterized both mechanically and geometrically. To improve the characterization, novel algorithms based on micro-computed tomography images and image segmentation techniques are implemented. Thereafter, elastic constants are estimated, informed by the characterization results. The method’s effectiveness is assessed through a deep comparison, based on the digital image correlation technique, between different experimental samples and finite element models. Results show that the numerical estimation provided in this work is accurate enough to develop realistic finite element models, including anisotropy of the structures. However, defects and voids developed during 3D printing are an important source of error for these numerical models. This work provides an estimation and validation of elastic constants in 3D-printed parts, including geometrical characterization, numerical homogenization and experimental validation. The results of this work provide valuable information encompassing techniques to improve the characterization of 3D-printed parts, tendencies on elastic constants, and main sources of error.