Improving the strength of fused filament fabrication parts by non-planar alignment of material extrusion wih stress vectors

Fused Filament Fabrication (FFF), a prominent additive manufacturing technique, has been limited in producing end-use parts due to significant anisotropy and weak interlayer bonding. This thesis presents a novel approach to improve mechanical properties of FFF-produced parts through non-planar alignment of material extrusion with stress vectors. Research progresses from initial proof-of-concept studies to developing comprehensive methodology for stress-aligned, non-planar toolpath generation. Work begins with investigating non-planar layer effects on part properties, demonstrating improvements in ductility and toughness. Building on these findings, a robust non-planar planning method is developed, generating stress-aligned layers and toolpaths feasible for consumer-grade hardware. This method utilises region-based stress alignment, interpolating between seed surfaces whilst preserving local boundaries and printability. Approach validation occurs through simulation and physical testing. Physical testing confirms mechanical property improvements, including increases in peak load (up to 22.7%), yield load (up to 34.0%), and energy absorption (up to 317.3%). Moreover, failure modes transitioned from brittle delamination to more ductile, fibre-oriented failures, indicating improved interlayer bonding, load distribution, and stress-aligned fibre realignment. This thesis extends non-planar layering frontiers for functional FFF parts, offering enhanced mechanical properties, efficient fabrication, and practical implementation on consumer-grade hardware, contributing to broader additive manufacturing adoption in end-use part production.

Author dc:creator

• Edwards, Rhys

Statement dc:rights

• info:eu-repo/semantics/openAccess
• The author owns the copyright in this thesis including all reproduction and reuse rights for the work. The work may not be altered without the permission of the copyright owner. Attribution is essential when quoting or paraphrasing from this thesis.
• © 2025 Rhys Edwards
• au.edu.uts.lib/cph

Language dc:language.iso

en_US

Handle dc:identifier.uri

http://hdl.handle.net/10453/190566

OAI identifier oai:identifier

oai:opus.lib.uts.edu.au:10453/190566