Prediction of Tensile Behavior in Additively Manufactured Polymer Matrix Composites via an Integrated Analytical Approach

Abstract

Additive manufacturing (AM) enables innovative product development through its material versatility and design freedom, further enhanced by advanced materials such as composites. A common example is the fabrication of polymer matrix composites (PMCs) via extrusion‐based AM. However, identifying optimal material–process combinations often requires costly and time‐consuming experiments. To address this challenge, this study proposes an analytical model for predicting the tensile mechanical properties of extrusion‐based additively manufactured PMCs. The model integrates classical laminate theory with volumetric considerations specific to material extrusion (ME) and accounts for key parameters, including fiber and matrix properties, layer thickness, nozzle diameter, and raster angle. The model is validated through tensile tests on ONYX specimens and comparison with literature data. Its predictive capability is also evaluated against previous approaches, including the rule of mixtures and the Halpin–Tsai model. Results show that the proposed model provides closer agreement with experimental findings across diverse cases, demonstrating its reliability and efficiency while reducing experimental effort. Finally, parametric studies are conducted using the validated model, and the effects of layer thickness, nozzle diameter, and fiber diameter on elastic modulus and stress are systematically analyzed.