Fused deposition modeling (FDM) is one of the most common 3D printing technologies and is becoming a well-established production method. Short fiber-reinforced polymers represent a new class of printing materials that enhance the mechanical properties of final components, thus informing an interesting subject of analysis for this study. FDM-printed parts are characterized by a strong anisotropy, so their behavior should be analyzed accordingly. The authors proposed a modeling strategy based on a transversely isotropic behavior hypothesis, representing material behaviors associated with an elasticity matrix in relation to the elastic field and a combination of Hill’s yield criterion and Voce’s isotropic hardening law for the plastic field. Material properties of materials were experimentally identified through tensile tests on dog bone specimens printed with different orientations in space. The numerical model was then calibrated using the finite element software LS-DYNA and the optimization software LS-OPT. An agreement between numerical and experimental results showed the robustness of the modeling strategy proposed to describe the stress behaviors of printed materials until a maximum load is reached, while strain behaviors have yet to be correctly defined due to the difficulties associated with evaluating an equivalent deformation.

Three-dimensional printing technology using fused deposition modeling processes is becoming more and more widespread thanks to the improvements in the mechanical properties of materials with the addition of short fibers into the polymeric filaments. The final mechanical properties of the printed components depend, not only on the properties of the filament, but also on several printing parameters. The main purpose of this study was the development of a tool for designers to predict the real mechanical properties of printed components by performing finite element analyses. Two different materials (nylon reinforced with glass or carbon fibers) were investigated. The experimental identification of the elastic material model parameters was performed by testing printed fully filled dog bone specimens in two different directions. The obtained parameters were used in numerical analyses to predict the mechanical response of simple structures. Blocks of 20 mm × 20 mm × 160 mm were printed in four different percentages of a triangular infill pattern. Experimental and numerical four-point bending tests were performed, and the results were compared in terms of load versus curvature. The analysis of the results demonstrated that the purely elastic transversely isotropic material model is adequate for predicting behavior, at least before nonlinearities occur.

Crashworthiness is an important issue in car body design: it describes the ability of the vehicle structure to behave efficiently by absorbing and dissipating energy in a stable and controlled manner during a crash event. Energy management during frontal impact is mainly done through crash boxes in the front rails. These crash boxes are usually slender, thin-walled steel columns, progressively collapsing during impact. Due to a trend in lightweight materials use, it is necessary to gain knowledge about the material behaviour and alternative joining systems. The use of an adhesive as a joining system for different materials was investigated by means of experimental tests on specimens and simple components, made of aluminium and deep drawing steel. A numerical simulation technique was developed to describe and understand the phenomenon. Furthermore, since the behaviour is influenced by the loading rate and the materials used in this application are known to be strain-rate sensitive, static and impact loading conditions were examined.

The development of particle accelerators with ever increasing energies is raising the standards of the structures which could interact with the particle beams. These structures could be subjected to strong shockwaves in accidental scenarios. In order to test materials in such conditions, one of the most promising techniques is the impact with high-power lasers. In view of the setting up of future experimental campaigns within the Petawatt High-Energy Laser for Heavy Ion Experiments (PHELIX), the present work aims at the development of a numerical approach for the simulation of graphite impacted by laser beams. In particular, the focus is on the spallation damage caused by shockwave reflection: a sufficiently intense laser beam could ablate the matter until plasma conditions, hence producing a shockwave which could travel inside the material and reach a free surface. A numerical model to properly describe the spall fragmentation of graphite has been calibrated on the basis of literature-available experimental data. The numerical approach is a ‘two-step’ procedure: the first step is the definition of the laser–matter interaction and the second one concerns the description of the shockwave evolution into matter. The simulations satisfactorily reproduce the dynamic response of graphite impacted by two different laser sources with various intensities, despite the difficulties of characterising a phenomenon which is extremely fast and chaotic.