Mechanical Characterization of 3D-Printed Scaffolds: A Multi-Objective Optimization Approach Using Virtual Testing and Homogenization

Abstract

A method to characterize the mechanical properties of cellular materials manufactured using 3D printing, specifically employing the fused deposition modeling (FDM) technique, is developed. Numerical simulations, virtual testing, and optimization based on genetic algorithms are combined in this approach to determine the anisotropic properties of the material, which are essential for biomedical applications such as tissue engineering. Homogenization using representative unit cells enabled the calculation of orthotropic properties, including elastic moduli ((Formula presented.), (Formula presented.), (Formula presented.)), Poisson’s ratios ((Formula presented.), (Formula presented.) and (Formula presented.)), and shear moduli ((Formula presented.), (Formula presented.), (Formula presented.)). These results validated the virtual tests using an L-shaped beam model, based on a known state of displacements and stresses. In the virtual test of the FDM model, a significant correlation with experimental results was observed, confirming the material’s anisotropy and its influence on deformations and stresses. Meanwhile, the effective medium test demonstrated over 95% agreement between simulated and experimental values, validating the accuracy of the proposed constitutive model. The optimization process, based on multi-objective genetic algorithms, allowed the determination of the material’s mechanical properties through controlled iterations, achieving a strong correlation with the results obtained from the homogenization model. These findings present a new approach for characterizing and optimizing 3D-printed materials using FDM techniques, providing an efficient and reliable method for applications in tissue engineering.