Threshold investigation of shell thickness for enhanced mechanical and tribological performance in 3D-printed curved sandwich structures

Global prominence has been attained by additive manufacturing technology in recent years, driven by its environmental benefits and machining advantages when compared to traditional subtractive methods. Fused deposition modeling (FDM) technology, primarily utilized in polymer and polymer composite 3D printing, allows for precise control of material distribution within components. In this study, mechanical and tribological behaviors of 3D-printed structures are investigated, yielding valuable insights applicable to practical scenarios. The study identifies threshold limits for layer thickness ratios in three-layered curved sandwich structures, which directly impact their specific load capacity. Stress distribution within 3D-printed PLA discs can be accurately predicted by a saturation function dependent on shell thickness, with material-specific constants. Beyond a critical shell thickness, the impact of increased shell thickness on local tribological properties is found to be negligible. These findings generalize effectively to structures characterized by robust outer shells and weaker inner infills. Connections are drawn between tribological behavior and contact mechanical properties, opening avenues for future research involving nonlinear material modeling and advanced simulations. This study contributes to a deeper understanding of 3D printing and polymer tribology while highlighting the transformative potential of additive manufacturing in various industries, offering cost-effective and resource-efficient solutions for optimized mechanical performance.