Deep Drawing of Additively Manufactured Composite Architected Discs: Effect of Infill Geometry and Feature Size on Formability

Additively manufactured composite architected discs offer a potential route for producing lightweight semi-finished blanks that can subsequently be shaped by conventional forming processes. However, the relationship between infill architecture, feature size, and deep-drawing formability remains poorly understood. This study investigates the deep-drawing response of material-extruded short-fibre-reinforced polymer composite discs by combining experimental tests and finite element simulations. Four infill strategies, namely perforated body, re-entrant, square and triangular, were first compared at drawing depths of 10 and 20 mm. The perforated body and re-entrant geometries were successfully formed at 10 mm, whereas only the perforated body withstood 20 mm without macroscopic failure. A second campaign focused on perforated discs with hole diameters of 2.5, 5, 7.5 and 10 mm. All configurations were drawable at 10 mm, while the 2.5 mm case failed at 20 mm. Statistical analysis confirmed that hole diameter significantly affected both retained cup height and side-hole aspect ratio. At 20 mm, larger holes reduced local ovalization but increased elastic recovery, leading to lower retained cup height. FEM simulations were used as an interpretative first-order model. They supported the experimental trends by comparing deformation modes, tensile/compressive stress redistribution, forming energy and strain localization. The results show that the formability of architected composite blanks is governed not only by material volume or porosity but by the ability of the internal architecture to accommodate deformation through a suitable balance between local stiffness and geometric compliance. These findings provide design-oriented guidelines for the development of additively manufactured architected blanks intended for hybrid additive–forming manufacturing routes.