A novel geometric predictive algorithm for assessing compressive elastic modulus in MEX additive processes, based on part nonlinearities and layers stiffness, validated with PETG and PLA materials

MEX (Material Extrusion) is an intrusive technological process that inherently induces alterations in the elastic and mechanical parameters of plastic materials. Manufacturers provide initial mechanical parameters for plastic filaments, which undergo modifications during MEX manufacturing, influenced by intrinsic manufacturing factors such as temperature and pressure changes, as well as geometric and technological parameters of the 3D additive process. These factors, compounded by the inherent geometric nonlinearities in plastic components, directly impact the post-manufacture mechanical and elastic properties of the material. Presently, material characterization in MEX manufacturing relies on manual experimental testing, necessitating new tests for any variation in manufacturing parameters. In this scenario of mechanical uncertainty, rigorously validating component behavior involves costly experimental trials. Intending to solve the problems of MEX components manufacturing, the paper presents an innovative methodology based on the use of a new predictive algorithm created by the researchers capable of obtaining the elastic modulus of a plastic material manufactured with MEX and its mechanical behavior in the elastic zone under compressive loads. The predictive algorithm only needs as input the compressive elastic modulus of the isotropic plastic material filament and the manufacturing parameters of the MEX process. The smart developed algorithm calculates the stiffness of each layer considering the number of holes in the projected area. The innovative predictive algorithm has been experimentally and numerically validated using PETG (Polyethylene Terephthalate Glycol) material and PLA (Polylactic Acid) on test specimens and on a case study of variable topology. The results show deviations from [0.2%–4.3%] for PETG and [0.4%] for PLA concerning the experimental tests and [1.1%–13.5%], to the numerical analyses. In this line, the presented algorithm greatly improves the results obtained by the simulation software since this software currently can not consider the geometric and technological parameters associated with the 3D manufacturing process of the component. The predictive algorithm is valid for each print pattern and manufacturing direction. The new algorithm improves the existing state of the art significantly since this algorithm extends its utility to most plastic polymer materials suitable for MEX 3D printing, provided that the mechanical and elast