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This study aims to investigate the tensile strength and elastic modulus of custom-designed polymer composites developed using voxel-based design. This study also evaluates theoretical models, such as the rule of mixtures, Halpin–Tsai model, Cox–Krenchel model and the Young–Beaumont model and the ability to predict the mechanical properties of particle-reinforced composites based on changes in the design of rigid particles at the microscale within a flexible polymer matrix.

This study leverages the PolyJet process for voxel-printing capabilities and a design of experiments approach to define the microstructural design elements (i.e. aspect ratio, orientation, size and volume fraction) used to create custom-designed composites.

The comparison between the predictions and experimental results helps identify appropriate methods for determining the mechanical properties of custom-designed composites ensuring informed design decisions for improved mechanical properties.

This work centers on multimaterial additive manufacturing leveraging design freedom and material complexity to create a wide range of composite materials. This study highlights the importance of identifying the process, structure and property relationships in material design.

The purpose of this study is to find the best geometries among the cylindrical, enamel and honeycomb geometries based upon the mechanical properties (tensile test, compression test and shear test). Further this obtained geometry could be used to fabricate products like exoskeleton and its supporting members.

The present research focuses on the mechanical testing of cylindrical, enamel and honeycomb-shaped parts fabricated through multi-jet printing (MJP) process with a wall thickness of 0.26, 0.33, 0.4 and 0.66 mm. The polymer specimens (for tensile, compression and shear tests) were fabricated using a multi-jet fusion process. The experimental results were compared with the numerical modelling. Finally, the optimal geometry was obtained, and the influence of wall thicknesses on various mechanical properties (tensile, compression and shear) was studied.

In comparison to cylindrical, enamel structures the honeycomb structures required less time to fabricate and had lower tensile, compressive and shear strengths. The most efficient geometry for fully functional parts where tensile, compressive and shear forces are present during application – cylindrical geometry is preferred followed by enamel, and then honeycomb. It was found that as the wall thickness of various geometries was increased, their ability to withstand tensile, compressive and shear loads also enhanced. The enamel shape structure exhibits greater strain energy storage capacity than other shape structures for compressive loads, and the strength to resist the compressive load will be lower. In the case of cylindrical geometries for tensile loading, the resisting area toward the loading will be higher in comparison to honeycomb- and enamel-based structures. At the same time, the ability to store the stain energy is less. The results of the tensile, compression and shear load finite element analysis using ANSYS are in agreement with those of the experiments.

From the insight of literature review, it is found that a wide range of work is done on fused deposition modeling (FDM) process. But in comparison to FDM, the MJP provide the better dimensional accuracy and surface properties (Lee et al., 2020). Therefore, it is observed that past research works not incorporated the effect of wall thickness of the embedded geometries on mechanical properties of the part fabricated on MJP (Gibson, n.d.). Hence, in this work, effect of wall thickness on tensile, compression and shear strength is considered as the main factor for the honeycomb, enamel and cylindrical geometries.

The fused filament fabrication (FFF) process is an additive manufacturing technique used in engineering design. The mechanical properties of parts manufactured by FFF are influenced by the printing parameters. The mechanical properties of rigid thermoplastics for FFF are well defined, while thermoplastic elastomers (TPE) are uncommonly investigated. The purpose of this paper is to investigate the influence of extruder temperature, bed temperature and printing speed on the mechanical properties of a thermoplastic elastomer.

Regression models predicting mechanical properties as a function of extruder temperature, bed temperature and printing speed were developed. Tensile specimens were tested according to ASTM D638. A 3×3 full factorial analysis, consisting of 81 experiments and 27 printing conditions was performed, and models were developed in Minitab. Tensile tests verifying the models were conducted at two selected printing conditions to assess predictive capability.

Each mechanical property was significantly affected by at least two of the investigated FFF parameters, where printing speed and extruder temperature terms influenced all mechanical properties (p < 0.05). Notably, tensile modulus could be increased by 21%, from 200 to 244 MPa. Verification prints exhibited properties within 10% of the predictions. Not all properties could be maximized together, emphasizing the importance of understanding FFF parameter effects on mechanical properties when making design decisions.

This work developed a model to assess FFF parameter influence on mechanical properties of a previously unstudied thermoplastic elastomer and made property predictions within 10% accuracy.

Additive manufacturing or “3D printing” is a rapidly expanding sector and is moving from a prototyping service to a manufacturing service in its own right. With a significant increase in sales, fused deposition modelling (FDM) printers are now the most prevalent 3D printer on the market. The increase in commercial manufacturing necessitates an improved understanding of how to optimise the FDM printing process for various product mechanical properties. This paper aims to identify optimum print parameters for the FDM process to achieve maximum tensile strength through a review of recent studies in this field.

The effect of the governing printing parameters on the tensile strength of printed samples will be considered, including material selection, print orientation, raster angle, air gap and layer height.

The key findings include material recommendations, such as the use of emerging print materials like polyether-ether-ketone (PEEK), to produce samples with tensile strength over 200 per cent that of conventional materials such as acrylonitrile butadiene styrene (ABS). Amongst other parameters, it is shown that printing in the “upright” orientation should be avoided (samples can be up to 50 per cent weaker in this orientation) and air gap and raster width should be concurrently optimised to ensure good “inter-raster” bonding. The optimal choice of raster angle depends on print material; in ABS for example, selecting a 0° raster angle over a 90° angle can increase tensile strength by up to 100 per cent.

The paper conclusions provide researchers and practitioners with an up-to-date, single point reference, highlighting a series of robust recommendations to optimise the tensile strength of FDM-printed samples. Improving the mechanical performance of FDM-printed samples will support the continued growth of this technology as a viable production technique.

The relationship between the bulk and localized mechanical properties is critically needed, especially to understand the mechanical performance of solder alloy because of smaller sizing trend of solder joint. The purpose of this paper is to investigate the relationship between tensile and nanoindentation tests toward the mechanical properties and deformation behavior of Sn-3.0Ag-0.5Cu (SAC305) lead-free solder wire at room temperature.

Tensile test with different strain rates of 1.5 × 10-4 s-1, 1.5 × 10-3 s-1, 1.5 × 10-2 s-1 and 1.5 × 10-1 s-1 at room temperature of 25°C were carried out on lead-free Sn-3.0Ag-0.5Cu (SAC305) solder wire. Stress–strain curves and mechanical properties such as yield strength (YS), ultimate tensile strength (UTS) and elongation were determined from the tensile test. Load-depth (P-h) profiles and micromechanical properties, namely, hardness and reduced modulus, were obtained from nanoindentation test. In addition, the deformation mechanisms of SAC305 lead-free solder wire were obtained by measuring the range of creep parameters, namely, stress exponent and strain rate sensitivity, using both of tensile and nanoindentation data.

It was observed that qualitative results obtained from tensile and nanoindentation tests can be used to identify the changes of the microstructure. The occurrence of dynamic recrystallization and the increase of ductility obtained from tensile test can be used to indicate the increment of grain refinement or dislocation density. Similarly, the occurrence of earliest pop-in event and the highest occurrence of pop-in event observed from nanoindentation also can be used to identify the increase of grain refinement and dislocation density. An increment of strain rates increases the YS and ultimate UTS of SAC305 solder wire. Similarly, the variation of hardness of SAC305 solder wire has the similar trend or linear relationship with the variation of YS and UTS, following the Tabor relation. In contrast, the variation of reduced modulus has a different trend compared to that of hardness. The deformation behavior analysis based on the Holomon’s relation for tensile test and constant load method for nanoindentation test showed the same trend but with different deformation mechanisms. The transition of responsible deformation mechanism was obtained from both tensile and nanoindentation tests which from grain boundary sliding (GBS) to grain boundary diffusion and dislocation climb to grain boundary slide, respectively.

For the current analysis, the relationship between tensile and nanoindentation test was analyzed specifically for the SAC305 lead-free solder wire, which is still lacking. The findings provide a valuable data, especially when comparing the trend and mechanism involved in bulk (tensile) and localized (nanoindentation) methods of testing.

The perfect interlacing of needle and bobbin thread in the stitch formation process and seam appearance depends first of all on correct pre‐tension of the tension regulator. Changes in the pre‐tension settings also have a direct influence on the tensile force during the sewing process. This contribution presents the influence of pre‐tension in a defined area on the tensile force in important phases of the stitch formation process. In addition the influence of the stitch velocity on tensile force was investigated. On the basis of statistic analysis it was ascertained in which pre‐tension area and stitch velocity the significant differences between tensile forces occurred.

This paper aims to review recent reports on mechanical properties of Sn-Bi and Sn-Bi-X solders (where X is an additional alloying element), in terms of the tensile properties, hardness and shear strength. Then, the effects of alloying in Sn-Bi solder are compared in terms of the discussed mechanical properties. The fracture morphologies of tensile shear tested solders are also reviewed to correlate the microstructural changes with mechanical properties of Sn-Bi-X solder alloys.

A brief introduction on Sn-Bi solder and reasons to enhance the mechanical properties of Sn-Bi solder. The latest reports on Sn-Bi and Sn-Bi-X solders are combined in the form of tables and figures for each section. The presented data are discussed by comparing the testing method, technical setup, specimen dimension and alloying element weight percentage, which affect the mechanical properties of Sn-Bi solder.

The addition of alloying elements could enhance the tensile properties, hardness and/or shear strength of Sn-Bi solder for low-temperature solder application. Different weight percentage alloying elements affect differently on Sn-Bi solder mechanical properties.

This paper provides a compilation of latest report on tensile properties, hardness, shear strength and deformation of Sn-Bi and Sn-Bi-X solders and the latest trends and in-depth understanding of the effect of alloying elements in Sn-Bi solder mechanical properties.

Fused deposition modelling (FDM) is increasingly being explored as a commercial fabrication method due to its ability to produce net or near-net shape parts directly from a computer-aided design model. Other benefits of technology compared to conventional manufacturing include lower cost for short runs, reduced product lead times and rapid product design. High-performance polymers such as polyetherimide, have the potential for FDM fabrication and their high-temperature capabilities provide the potential of expanding the applications of FDM parts in automotive and aerospace industries. However, their relatively high glass transition temperature (215 °C) causes challenges during manufacturing due to the requirement of high-temperature build chambers and controlled cooling rates. The purpose of this study is to investigate the mechanical properties of ULTEM 1010, an unfilled polyetherimide grade.

In this research, mechanical properties were evaluated through tensile and flexural tests. Analysis of variance was used to determine the significance of process parameters to the mechanical properties of the specimens, their main effects and interactions. The fractured surfaces were analysed by scanning electron microscopy and optical microscopy and porosity was assessed by X-ray microcomputed tomography.

A range of mean tensile and flexural strengths, 60–94 MPa and 62–151 MPa, respectively, were obtained highlighting the dependence of performance on process parameters and their interactions. The specimens were found to fracture in a brittle manner. The porosity of tensile samples was measured between 0.18% and 1.09% and that of flexural samples between 0.14% and 1.24% depending on the process parameters. The percentage porosity was found to not directly correlate with mechanical performance, rather the location of those pores in the sample.

This analysis quantifies the significance of the effect of each of the examined process parameters has on the mechanical performance of FDM-fabricated specimens. Further, it provides a better understanding of the effect process parameters and their interactions have on the mechanical properties and porosity of FDM-fabricated polyetherimide specimens. Additionally, the fracture surface of the tested specimens is qualitatively assessed.

Polyetheretherketone (PEEK) is used to manufacture biomedical implants because it has a high strength-to-weight ratio and high strength and is biocompatible. However, the use of fused deposition modeling to print a PEEK results in low strength and crystallinity. This study aims to use the Taguchi method to optimize the printing factors to obtain the highest tensile strength of the printed PEEK object. The annealing effect on printed PEEK object and crystallinity are also investigated.

This study determines the printing factors including the printing speed, layer thickness, printing temperature and extrusion width. Taguchi experimental design with a L9 orthogonal array is used to print the tensile specimen and carried out the tensile test to compare the tensile strength and porosity. Analysis of variance (ANOVA) is used to determine the experimental error and to determine the optimization printing parameters to obtain the highest tensile strength. A multivariate linear regression analysis is used to obtain the linear regression equation for predicting the theoretical tensile strength. An X-ray analysis is achieved to evaluate the crystalline of printed object. The effect of annealing is investigated to improve the tensile strength of printed part. An intervertebral lumber device is printed to demonstrate the feasibility of the obtained optimization parameters for practical application.

Taguchi experiment designs nine sets of parameters to print the PEEK tensile specimen. The experimental results and the ANOVA present that the order in which the factors affect the tensile strength for printed PEEK parts is the layer thickness, the extrusion width, the printing speed and the printing temperature. The optimized printing parameters are a printing speed of 5 mm/s, a layer thickness of 0.1 mm, a printing temperature of 395 °C and an extrusion strand width of 0.44 mm. The average tensile strength of printed specimen with the optimized printing parameters is 91.48 MPa, which is slightly less than the theoretical predicted value of 94.34 MPa. After annealing, the tensile strength increases to 98.85 MPa, which is comparable to that for molded PEEK and the porosity decreases to 0.3 from 3.9%. X-ray diffraction results show that all printed and annealed specimens have a high degree of crystallinity. The printed intervertebral lumber device has ultimate compressive load of 13.42 kN.

The optimized printing parameters is suitable for low-price fused deposition modeling machine because it does not involve a table at high temperature and can print the PEEK object with high tensile strength and good crystalline. Annealing parameters offer a good solution for tensile strength improvement.

The weld region obtained during friction stir welding (FSW) of metallic materials (including aluminum alloys) contains typically well-defined zones, each characterized by fairly unique microstructure and properties. The purpose of this paper is to carry out combined experimental and numerical investigations of the mechanical properties of materials residing in different weld zones of FSW joints of thick AA2139-T8 plates.

Within the experimental investigation, the following has been conducted: first, optical-microscopy characterization of the transverse sections of the FSW joints, in order to help identify and delineate weld zones; second, micro hardness field generation over the same transverse section in order to reconfirm the location and the extent of various weld zones; third, extraction of miniature tensile specimens from different weld zones and their experimental testing; and finally, extraction of a larger size tensile specimen spanning transversely the FSW weld and its testing. Within the computational investigation, an effort was made to: first, validate the mechanical properties obtained using the miniature tensile specimens; and second, demonstrate the need for the use of the miniature tensile specimens.

It is argued that the availability of weld-zone material mechanical properties is critical since: first, these properties are often inferior relative to their base-metal counterparts; second, the width of the weld in thick metallic-armor is often comparable to the armor thickness, and therefore may represent a significant portion of the armor exposed-surface area; and finally, modeling of the weld-material structural response under loading requires the availability of high-fidelity/validated material constitutive models, and the development of such models requires knowledge of the weld-material mechanical properties.

The importance of determining the mechanical properties of the material in different parts of the weld zone with sufficient accuracy is demonstrated.