Quantifying the effect of embedded component orientation on flexural properties in additively manufactured structures

In-situ embedding with Additive Manufacturing (AM) enables a user to insert functional components in a part by pausing the print, inserting the component into a specially designed cavity, and then resuming the print. This introduces the capability to merge the reliable functionality of external parts into AM structures, allowing multifunctional products to be manufactured in a single build. Previous research has shown that process interruption introduces weaknesses at the paused layer, and the presence of an embedding cavity further reduces the maximum tensile strength of the part. The research presented in this paper expands this understanding by investigating the impact of the process and design considerations for embedding on the strength of the material extrusion parts. A cuboidal geometry is embedded with different orientations with a flush surface at the paused layer, and tested for maximum bending strength. The findings help to further design guidelines for embedding with material extrusion AM.