Additively manufactured polymer structures often exhibit strong anisotropies due to their layered composition. Although existing methods in additive manufacturing (AM) for improving the mechanical properties are available, they usually do not eliminate the high degree of structural anisotropy. Existing methods for continuous fiber (cF) reinforcement in AM can significantly increase the mechanical properties in the strand direction, but often do not improve the interlaminar strength between the layers. In addition, it is mostly not possible to deposit cFs three-dimensionally and curved (variable–axial) and, thus, in a path that is suitable for the load case requirements. There is a need for AM methods and design approaches that enable cF reinforcements in a variable–axial way, independently of the AM mounting direction. Therefore, a novel two-stage method is proposed in which the process steps of AM and cF integration are decoupled from each other. This study presents the development and validation of the method. It was first investigated at the specimen level, where a significant improvement in the mechanical properties was achieved compared to unreinforced polymer structures. The Young’s modulus and tensile strength were increased by factors of 9.1 and 2.7, respectively. In addition, the design guidelines were derived based on sample structures, and the feasibility of the method was demonstrated on complex cantilevers.

Fibre-reinforced polymers based on natural fibers, such as flax fibers, exhibit pronounced nonlinear orthotropic material behavior. This presents a significant challenge in finite element analysis (FEA) simulations, as the nonlinear constitutive models available in commercial FEA tools are difficult to apply and fail to capture all the material’s specific characteristics. Relying on initial or reduced secant moduli in linear quasi-static analyses of deformations or stress states can result in inaccurate outcomes and overly optimistic strength predictions, particularly in compression-dominated cases. However, with appropriate modifications, classical laminate theory (CLT) can be adapted for nonlinear analysis. This involves iteratively updating the components of the stiffness matrix for the unidirectional (UD) ply during the calculation process based on the current strain state and stress interactions. This study presents and discusses a computational algorithm for the FEA software ABAQUS/CAE 2019, which incorporates material-related orthotropic nonlinearities and stress-dependent interactions within the CLT framework. The algorithm represents a single-scale material model at the meso level (UD ply) and is based on the concept of orthotropic elasto-damage within the framework of continuum damage mechanics (CDM) theory. Numerical implementation is achieved through a user-defined field (USDFLD) subroutine, accompanied by a pre-processing Python script for managing experimental data, computing data fields, and calculating parameters. As shown below, this type of implementation appears justified compared to a user material subroutine (UMAT) subroutine in terms of computational efficiency and practicality.

This study focuses on a novel lightweight technology for manufacturing variable-axial fiber-reinforced polymer components. In the presented approach, channels following the load flow are implemented in an additively manufactured basic structure and impregnated continuous fiber bundles are pulled through these component-integrated cavities. Improved channel cross-section geometries to enhance the mechanical performance are proposed and evaluated. The hypothesis posits that increasing the surface area of the internal channels significantly reduces shear stresses between the polymer basic structure and the integrated continuous fiber composite. A series of experiments, including analytical, numerical, and microscopic analyses, were conducted to evaluate the mechanical properties of the composites formed, focusing on Young’s modulus and tensile strength. In addition, an important insight into the failure mechanism of the novel fiber composite is provided. The results demonstrate a clear correlation between the channel geometry and mechanical performance, indicating that optimized designs can effectively reduce shear stress, thus improving load-bearing capacities. The findings reveal that while fiber volume content influences the impregnation quality, an optimal balance must be achieved to enhance mechanical properties. This research contributes to the advancement of production technologies for lightweight components through additive manufacturing and the development of new types of composite materials applicable in various engineering fields.

Lesions in the cartilage of the knee can lead to degenerative arthritis of the joint. Therefore, procedures such as osteochondral grafting are used to repair the cartilage. Osteochondral grafting procedures are of interest, because the lesion is replaced with true hyaline cartilage. This procedure involves press-fitting a cylindrical bone-cartilage plug by impaction to repair the damaged cartilage area. Recently, it has been shown that impact insertion of osteochondral grafts generates damaging loads that cause chondrocyte death, particularly in the superficial zone [1]. Using high speed video analysis, it has been shown that the highest local deformations occur within the superficial zone of the osteochondral plug [2,3]. However, the exact strain condition of the tissue during impaction and any depth dependent strain differences remain unknown. Assuming uniaxial load conditions of an ideal cylinder exposed to high strain rates, the stress-strain response of cartilage plugs during the impaction process is reported in this study. We hypothesized that the highest strain levels would occur in the superficial zone. Based on the experimental results, the fundamental material effects substantial for the load case under consideration can be studied. Consequently, suitable material models for subsequent numerical simulations can be established.