Academic Thesis
Hybrid Reinforcement strategies for FDM 3D Printing
Why did I do this project?
This thesis focused on exploring how large-scale 3D printed components can be reinforced for load-bearing structural applications.
Standard FDM prints often fall short in mechanical performance. Through this work, I aimed to evaluate how hybrid reinforcement strategies — foam filling and glass fiber laminates — could improve strength and stiffness.
Materials / Software / Techniques Used:
• PLA-CF filament (10% short carbon fiber) for core printing
• PU foam for internal infill reinforcement
• Glass fiber laminates via vacuum infusion
• Thermal annealing, epoxy bonding
• Tools: Fusion 360, nTop, Abaqus, Blade Slicer
• Tests: Tensile, 4-point bending, SEM, XRD, DIC
What did I learn?
I learned how to apply post-processing strategies like thermal annealing and structural hybridization effectively. Foam and laminate reinforcements both introduced new challenges and taught me how to think about scaling material choices for real-world applications. Advanced testing and modeling helped validate the designs.
Results:
Four types of specimens were developed:
– Core Only (CO)
– Core + Foam (CF)
– Core + Laminate (CL)
– Core + Foam + Laminate (CFL)
The CFL specimens showed the best overall structural performance, combining improved stiffness, energy absorption, and durability. Foam filling improved impact response, while glass laminates added significant flexural strength. Annealing helped improve stiffness but came at a slight cost in ductility — a tradeoff depending on the use case.
A full research article based on this work is under preparation (to be published in 2025).
Please contact me if you’d like to know more or collaborate on related research.