Enhanced prediction of mechanical properties in interwoven 3D-printed structures by integrating finite element analysis and design of experiments

Representative volume element (RVE) models have been widely used to study the influence of additive manufacturing parameters on the mechanical properties of 3D-printed components. However, prior work primarily focused on simple infill patterns, often neglecting the complexities of interwoven geometries. This study introduces a methodology that integrates finite element analysis (FEA) with a statistical approach to predict the mechanical properties of novel interwoven structures produced by the z-stitching technique. Enhanced performance characteristics are explored by strategically aligning and stitching filaments in multiple planes. The FEA approach is grounded in meso-mechanical analyses using RVEs to predict effective orthotropic properties, specifically evaluating stress–strain behavior, modulus of elasticity, and strength. Mechanical properties derived from FEA-based homogenization were validated against experimental tensile tests. The combined use of numerical modeling and statistical analysis enables an efficient, iterative design process for complex 3D-printed structures, reducing computational demands and experimental efforts.