Finite Element Evaluation of Failure in Additively Manufactured Continuous Fiber-Reinforced Composites

In the attempt of increasing resource efficiency and reducing carbon emissions, the development of lightweight designs in structural applications is essential. In addition, the lightweight structures often follow complex topologically optimized designs which are more suitable for the application of additive, in contrast to conventional manufacturing techniques. Within the additive manufacturing process, constituents may be combined to design and produce durable and lightweight materials with predefined mechanical, electrical and thermal properties, while also accounting for their sustainability and recyclability. Regretfully, due to the lack of research in material behavior, the additive manufacturing technology implementation in engineering applications is still limited in comparison to traditional manufacturing methods. While the potential of additively manufactured continuous fiber composites has already been recognized in the scientific community, constitutive modeling and damage resistance are seldom reported. Since fiber-reinforced composite structures are rarely designed as unidirectional, this study is focused on numerical analysis of failure for multi-directionally reinforced composite laminates loaded in a uniaxial direction. Specimens are modeled and evaluated using a progressive damage model, proposing guidelines for safer design and application.