Investigation of uncertainties in tensile test results due tothe material extrusion-based production of lattice structures

With the continuous development of technology, material extrusion-based additive manufacturing, also known as fused filament fabrication (FFF), has found widespread use in various fields ranging from engineering to medicine. This method, also referred to as 3 dimensional (3D) printing technology, offers significant advantages such as design flexibility, cost efficiency, and the reduction of material waste. Compared to traditional manufacturing methods, this technology enables the creation of more complex and unique designs, providing innovative solutions especially in sectors such as automotive, aerospace, and biomedical engineering. Furthermore, its rapid prototyping capabilities accelerate design processes and shorten production cycles. In recent years, the rapid advancements in 3D printing technologies have revolutionized industrial production processes, enabling the development of lighter and more durable structures. In this context, lattice structures produced using the FFF method with polylactic acid (PLA), a biodegradable thermoplastic polymer, stand out with their innovative designs and versatile application potential. These structures are designed to optimize material use while meeting high-performance and low-weight requirements. Particularly in critical applications such as vehicle bodies, energy absorption structures, and biomedical implants, significant successes have been achieved. However, uncertainties observed in the mechanical properties of lattice structures produced via FFF, particularly in parameters such as tensile strength and stiffness, pose a major challenge to their design and production processes. This study aims to examine the uncertainties in the mechanical properties of single lattice cells manufactured using PLA through FFF under tensile testing. To minimize production costs, single-cell samples were used, and two different designs were developed. The first design employed cells fixed with high-strength adhesives, while the second incorporated integrated fixtures made of PLA. Deformation behaviors were thoroughly analyzed using video recordings captured during tensile tests, and probability distribution functions were applied to the mechanical property data. The findings revealed the effects of different lattice types and strut diameters on mechanical properties, providing significant insights for achieving higher reliability and performance in the design and production processes of these structures. The use of lattice structures produced via FFF, particularly in the automotive, aerospace, and biomedical sectors, has proven to be an effective solution addressing the specific needs of these industries. The results of the study suggest that the FFF method has the potential to facilitate the development of more complex and durable structures in the future, increasing its adoption in both engineering and biomedical applications. This study aims to provide a comprehensive understanding of the uncertainties in the mechanical properties of lattice structures produced via FFF, guiding the control and optimization of these uncertainties. The research contributes to the development of more efficient, lightweight, and durable solutions in industrial applications.