Prediction and validation of composite mechanical properties resulting from voxel-based microstructural design in material jetting

Purpose: This study aims to investigate the tensile strength and elastic modulus of custom-designed polymer composites developed using voxel-based design. This study also evaluates theoretical models, such as the rule of mixtures, Halpin–Tsai model, Cox–Krenchel model and the Young–Beaumont model and the ability to predict the mechanical properties of particle-reinforced composites based on changes in the design of rigid particles at the microscale within a flexible polymer matrix. Design/methodology/approach: This study leverages the PolyJet process for voxel-printing capabilities and a design of experiments approach to define the microstructural design elements (i.e. aspect ratio, orientation, size and volume fraction) used to create custom-designed composites. Findings: The comparison between the predictions and experimental results helps identify appropriate methods for determining the mechanical properties of custom-designed composites ensuring informed design decisions for improved mechanical properties. Originality/value: This work centers on multimaterial additive manufacturing leveraging design freedom and material complexity to create a wide range of composite materials. This study highlights the importance of identifying the process, structure and property relationships in material design.