This study presents a case-specific joining method for modular, large-scale components manufactured using Selective Laser Sintering (SLS). A T-slot joint reinforced with a pultruded carbon fiber rod was developed to enable the segmental assembly of polymer fan blades that exceed the build volume of common SLS printers. Through an iterative design process, five joint variations were investigated, focusing on the optimization of slot geometry (fillet radii and wall thickness) and the integration of carbon fiber reinforcements to create a high-strength hybrid connection. The experimental findings were validated using a non-linear finite element analysis (FEA) utilizing an iteratively calibrated Young’s modulus of 710 MPa, which accounts for the 50/50 virgin-to-reused PA2200 powder ratio employed in the study. The numerical model identified that the primary sites for crack initiation were the fillet radii of the female slot, where localized equivalent plastic strains reached critical levels of up to 84% in tension and 78% in bending. The final design achieved an average tensile strength of 27.6 MPa, exceeding the design threshold of 21.9 MPa with a safety factor of 2.5. While unreinforced joints showed a 73.4% reduction in bending strength compared to solid specimens, the addition of an 8 mm carbon rod increased performance by 238.7%, restoring over 90% of the monolithic material’s strength. Numerical results confirmed that the reinforcement assumed the primary load-bearing role, effectively mitigating stresses in the polymer matrix below the ultimate tensile strength. Failure analysis clarified that the observed audible failure originated from internal fiber breakage within the rod at stresses between 900–1050 MPa. This work demonstrates that a segmental, reinforcement-based joining method can effectively overcome size constraints in polymer additive manufacturing, providing a robust and repeatable solution for rotating components subject to complex loading conditions.
Bašťovanský et al. (Fri,) studied this question.