ADVANCED STRESS ANALYSIS OF LONG FIBRE COMPOSITE COMPONENTS MADE WITH ADDITIVE MANUFACTURING

Additive Manufacturing (AM), commonly known as 3D printing, has revolutionized traditional manufacturing by enabling the production of intricate and customized structures. It brings advantages such as the creation of components with complex geometries and the potential for cost savings, especially in scenarios with low production volumes. However, drawback of this technology exists, notably the propensity for unwanted porosity in parts. Among the various technologies falling under the umbrella of Additive Manufacturing, this thesis focuses on Fused Deposition Modeling (FDM), prevalent in the field of composite materials. The main contributions of the thesis include the development of several analytical models that consider the effects of defects and design features introduced by FDM manufacturing processes. These models specifically address stress states in composite bodies, focusing on factors like porosities and localized reinforcements. The analytical models are validated against Finite Element methods, demonstrating their reliability in describing stress field in the studied areas. Despite the challenges posed by AM, the analytical models presented in this thesis serve as a robust foundation for developing effective tools to predict the elastic behavior and fatigue life of components manufactured using additive manufacturing technology, particularly in the context of FDM.