Experimental Characterization and Numerical Optimization of 3D-Printed PA6-CF External Fixator Rings

This research investigated the feasibility of 3D-printed external fixator (EF) rings made from carbon fiber reinforced polyamide 6 (PA6-CF) as an alternative to the conventional metallic counterpart. The study integrated tensile testing with digital image correlation (DIC) in as-printed and cold plasma-sterilized conditions, finite-element analysis (FEA) under wire loading, topology optimization for material and energy reduction, and evaluation of printability limits for large PA6-CF rings. The average Young’s modulus was 4.76 GPa and the maximum tensile strength was 60.5 MPa for as-printed samples, decreasing by 6.4% and 10.4% after sterilization, respectively. Using these properties as model inputs, FEA predicted safety factors larger than 1.42 for all configurations under 1000 N wire pretension, while topology optimization targeted up to 50% mass reduction without compromising ring stiffness. The study also revealed challenges in the printability of PA6-CF for large and thin components, including dimensional contraction, significant warping and moisture-induced defects, requiring an experienced 3D printer operator.