Failure analysis of fused deposition modeling 3D printed poly lactic acid polymer

Additive manufacturing, commonly known as 3D printing (AM), has emerged as one of the most transformative technological advances in the last few decades in global manufacturing, as it allows for the production of intricate components without the use of costly molds. Fused Deposition Modeling (FDM) is widely adopted among various AM techniques due to its accessibility and effectiveness. FDM 3D-printed PLA (Poly Lactic Acid) shows a transversely isotopic symmetry similar to laminated composite structures. Therefore, classical lamination theory can be applied to FDM 3D-printed PLA. This study attempts to expand the knowledge by relying on classical lamination theory and several imposed failure theories like maximum stress, Tsai-Hill, Tsai-Wu, and Hashin to determine how FDM 3D printing of PLA fails. We investigate eight different raster orientations (0°, 10°, 15°, 30°, 45°, 60°, 75°, and 90°) and compare the theoretical prediction of strength with experimental findings. With this comprehensive analysis, we are seeking to better understand the failure analysis of FDM 3D printed PLA. The maximum stress, Tsai-Wu, Tsai-Hill, and Hashin failure theories show good agreement with experimental findings for 0°and 90° raster orientations. As the raster orientation shifts from 0°, the discrepancy between experimental results and theoretical predictions increases, peaks at mid-angles, and then decreases, becoming negligible at 90°.