Strength Analysis of Additive Parts with Variation in Infill Percentage for ABS Materials

In John Deere additive manufacturing, one of the significant challenges in additive manufacturing is determining the optimal infill percentage, as it directly affects the mechanical strength of printed components. Designers often find it difficult to decide on this percentage due to the lack of clear guidelines and empirical data. This study addresses this gap by investigating the strength characteristics of additive ABS30 material parts with varying infill percentages, specifically ranging from 10% to 100% (full solid). Despite existing literature, there is a notable absence of comprehensive studies on the relationship between infill percentage and strength, primarily due to the complexities involved in creating and exporting accurate infill models from additive manufacturing software. To tackle this issue, we developed CAD models designed for tensile, compression, and bending tests as per ASME, incorporating line infill patterns at various infill percentage. We then performed virtual validation using HyperMesh to conduct stress analysis, to have theoretical predictions. Subsequently, the tensile, compressive and bending samples were 3D printed using an Ultimaker 5S printer with varying infill percentage. Following the printing process, we conducted experimental investigations to compare the actual mechanical performance of the samples with our validation results. Through this comprehensive approach, we established a correlation between infill percentage and mechanical strength. This study enhances the understanding of how infill percentage impacts strength as well as provides practical guidance for engineers in selecting appropriate infill settings for their additive manufacturing applications.