Three-dimensional (3D) printing technology has transformed manufacturing by enabling the creation of complex geometries with ease. Yet, optimizing the mechanical performance of printed parts remains a challenge, especially when balancing strength, material usage, and print time. Traditional mechanical testing in additive manufacturing often relies on specimens with 100% infill, overlooking the design potential of variable infill densities.
This study introduces a novel approach by explicitly modeling internal infill structures in CAD (Creo Parametric) across a range of densities (10% to 100%) and validating their mechanical behavior through both finite element analysis (FEA) in ANSYS and standardized physical testing (ASTM D638 for tensile, ASTM D695 for compressive, and ASTM D790 for flexural properties). Unlike prior studies that rely on slicer-generated infill patterns, this method enables precise control and repeatability in simulation and testing.
The results demonstrate how infill density influences mechanical properties and assess the predictive accuracy of simulation-based methods. By linking internal structure design with mechanical performance, this research advances the state of the art in additive manufacturing, offering a pathway to more efficient, application-specific design strategies.