3D Printed Beam with Optimized Internal Structure—Experimental and Numerical Approach

This article compares the results of numerical and experimental analysis of the mechanical properties of an optimized 3D-printed beam. The samples were subjected to a four-point bending test, and corresponding numerical models were created at the same time. The beams were printed using 3D printing and their weight was reduced by using an internal spatial grid with variable thickness that gradually increases towards the outer walls. This approach allows for effective optimization of material strength while minimizing raw material consumption during production. One of the key findings is the determination of the ultimate strength between fibers, the mode of failure, and the high agreement between the experimental results and the numerical model using the finite element method. The optimized beam achieved nearly 60% weight reduction while maintaining comparable load-bearing capacity. The knowledge gained opens up new possibilities in the field of materials engineering and also makes a significant contribution to the methodology of developing and optimizing these structures using 3D printing technology.