Additively fabricated innovative material: numerical prediction and experimental comparison of fracture toughness

Every functional component in current industries requires unique and adaptable behavior for the materials. The process of forming new composite materials requires time and significant cost. The goal of this study is to fabricate novel materials using alternative layers of various materials, such as poly-lactic acid (M1), wood reinforced poly-lactic acid (M2) and ceramic reinforced poly-lactic acid (M3), fabricated using fused deposition modeling. The evaluation of fracture toughness is essential for materials to ensure its applicability for their intended use. Extended finite element method and experimentation were used to evaluate fracture toughness. The results show that, when compared to poly-lactic acid M1 (fracture toughness at mode I = 4.84 MPa√m), wood reinforced poly-lactic acid M2 (fracture toughness at mode I = 3.25 MPa√m), and ceramic reinforced poly-lactic acid M3 (fracture toughness at mode I = 5.76 MPa√m), the innovative material exhibits superior fracture toughness at mode I = 16.54 MPa√m (experimentally) and fracture toughness at mode I = 17.15 MPa√m (simulation). Equivalent experimental and extended finite element method outcomes provide two levels of assurance, giving fidelity and allowing incorporation of innovative material potential in lightweight application that demand high fracture resistance. This study offers first-hand experience for implementing innovative material in a variety of industrial and structural application.