Experimental Investigation of 3D-Printed Structures from Wood-Based Polymer Composites

This study investigated the mechanical and physical properties of a wood-based polymer composite DuraSense® 3D S51 Flex K to enhance its potential in large-scale additive manufacturing. While wood-based polymer composites are already used in applications such as furniture, a deeper understanding of their behaviour, particularly regarding printing orientation and structural performance, could expand their use in new industries, enhancing sustainable material and manufacturing techniques. To assess performance, hollow cubes were 3D-printed from the mentioned composite and cut into samples oriented at 0°, 30°, 45°, and 90° to the printing direction. Tensile strength, flexural strength, modulus of elasticity, hardness, water absorption, thermal properties and microstructure were defined for the samples. The 0° specimens exhibited the highest tensile (15.39 MPa) and flexural strength (26.05 MPa), while the 90° orientation specimens showed reductions in strength of 72% and 69%, respectively. The modulus of elasticity also decreased by 71% at 90°, confirming anisotropy. Additional tests revealed a Brinell hardness of 179.9 N/mm², a water absorption of 19.75%, with minimal dimensional change, and a thermal conductivity of 0.1553 W/m·K. Microscopic analysis showed porosity and uneven fibre distribution, indicating the need for composite optimisation. These findings confirm the importance of orientation-aware design in large-scale additive manufacturing and provide the background for future work focusing on the development of printing strategies and computational modelling to enhance print quality, interlayer adhesion, and performance in applications.