Purdue University Graduate School
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posted on 2022-12-07, 19:59 authored by Omar AlGafriOmar AlGafri


This thesis is motivated by the author’s observation that no systematic methodology is available to characterize and model mechanical behaviors of 3D printed parts in terms of their elastic modulus and critical loading capacities. Note that the more controlled and steadier printing process is, the easier the mechanical properties parts can be predicted. This research focuses on the methods for the prediction and validation of mechanical properties of 3D printed parts, and the focus is the responses of the printed parts subjected to tensile loads. The mathematic models are derived to characterize the mechanical properties of a part along three principal directions, and the models are validated experimentally by following the American Society for Testing and Materials (ASTM) D638 testing standards. It is assumed that a unidirectional plane stress occurs to each lamina to (1) simplify a compliance matrix with a size 3 by 3 and (2) characterize the mechanical properties by the elastic modules and strengths in three principal directions. Two mathematical models are developed using the experimental data from the classical laminate theory and finite element analysis (FEA) by the SolidWorks. Both of the developed models are used to predict the ultimate tensile strength and Young’s modulus of the specimens that are printed by setting different raster angles on different layers. This thesis work aims to (1) gain a better understanding of the impact of printing parameters on the strengths of printed parts and (2) explore the feasibility of using the classical laminate theory to predict the mechanical properties of the parts printed with different raster angles and patterns. To validate the proposed mathematic models, parts by FDM are tested by following the ASTM testing standards; moreover, it testifies if the selected ASTM-D638 is suitable to test 3D printed parts by FDM. 


Degree Type

  • Master of Science


  • Mechanical Engineering

Campus location

  • Fort Wayne

Advisor/Supervisor/Committee Chair

Dr. Zhuming Bi, Chair

Advisor/Supervisor/Committee co-chair

Dr. Nashwan Younis

Additional Committee Member 2

Dr. Donald Mueller