Effect of layer orientation and infill density on reliability and lifetime of FDM-printed conductive composites under tensile loading
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https://orcid.org/0009-0003-3493-2519
Fatima Zahra Karmil
Laboratory of Physical Chemistry of Materials, Department of Chemistry, Faculty of Sciences, University Chouaïb Doukkali,
Narjisse Douiri
Electrical Engineering and Intelligent Systems Laboratory (EEIS), ENSET Mohammedia, Hassan II University of Casablanca, Morocco
Fouad Ait Hmazi
Laboratory of Nuclear, Atomic, Molecular, Mechanical and Energetic Physics, Chouaib Doukkali University, El Jadida, Morocco
Hachimi Taoufik
Ecole Normale Supérieure (ENS), Moulay Ismaïl University, BP. 3104, Toulal, Meknes, Morocco
Fatima Majid
Laboratory of Nuclear, Atomic, Molecular, Mechanical and Energetic Physics, Chouaib Doukkali University, El Jadida, Morocco
Abstract
Conductive composites have attracted growing interest in recent years in the field of additive manufacturing, especially for functional and structural applications. Nevertheless, their mechanical behavior and durability remain highly influenced by 3D printing methods and parameters. This paper investigates the combined effect of layer orientation and infill density on the mechanical damage and reliability of PLA-CB conductive composites manufactured by filament deposition modeling (FDM) technology. Tensile tests were performed on specimens printed with different layer orientations (0°, 45° and 90°) and infill densities (20%, 40%, 60%, 80% and 100%) to analyze the evolution of damage and the dispersion of mechanical properties. Analysis of damage evolution was used to model failure probability, assess material reliability, and predict service life based on 3D printing parameters. The results indicate that infill density significantly influences mechanical strength and performance stability, while layer orientation also plays a key role in the failure mechanism. The 0° orientation (parallel to the tensile direction) offered the best mechanical performance. At 45°, the results show intermediate behavior between stiffness and flexibility due to the distribution of shear stresses between layers. However, samples printed at 90° show much lower strength, dominated by delamination between layers. This study thus proposes a useful predictive framework for optimizing the printing parameters of PLA-CB conductive composites and contributes to a better understanding of their behavior in service for applications requiring reliable and durable mechanical performance.
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