Explaining the Difference Between Real Part and Virtual Design of 3D Printed Porous Polymer at the Microstructural Level

The combination of experimental and numerical approaches is attempted to shed more light on 3D microstructural imperfections and mechanical performance of 3D printed acrylonitrile butadiene styrene parts. The starting point is the virtual building of airy structures using a reverse engineering approach. This approach combines microstructure generator, finite element model, and optimization strategy to propose virtual airy structures satisfying structural and mechanical criteria up to a desired porosity content of 60%. Optimal structures are printed using fused deposition modeling and X‐ray microtomography is used to assess all microstructural defects. Compression testing is performed for load levels above 50% of reduction in sample height. The main outcome of this work is the demonstration of small amount of process induced porosity inducing high pore connectivity. The interdependence of process induced and desired porosity reveals genuine microstructural effects that are only characteristics of 3D printed materials.