In this research study, the design and fabrication workflow of functionally graded materials (FGMs) were introduced using fused filament fabrication (FFF) process. Rigid polymers were mechanically characterized in three printing directions. Tensile strength and modulus of elasticity values for YZ and XY printing orientation specimens indicated similar results. Printing in the XZ direction showed poor strength values in comparison with other printing directions. Interface analysis with different transition patterns was accomplished and the advantage of gradient transition was achieved. Micrography of specimens was analyzed to investigate the internal structure and was used to validate the test results. Statistical methods were applied to investigate the relationship between microstructural descriptors (volume fractions) and process-related parameters (printing temperatures). The results of the analysis of variance (ANOVA) have confirmed that printing temperature and concentration have a significant impact on tensile test results. The data-driven approach was employed to construct a linear regression models in order to formulate input data for finite element analysis (FEA). As a result of FEA simulation, effective Young’s modulus was calculated using a MATLAB code. FEA-predicted Young’s moduli were validated through experimental test results. The comparison of the numerical method and experimental values showed less than 5% error for FGM specimens printed in 250, 260 and 270 °C temperatures. FFF process with FGM could have potential applications in medical, structural, and automotive industries by locally varying material properties. This study presents a unique method of fabricating FGM structures with low-cost manufacturing process.

在这项研究中，功能性梯度材料（FGM）的设计和制造工作流程是采用熔丝制造（FFF）工艺引入的。在三个印刷方向上对刚性聚合物进行了机械表征。YZ和XY印刷方向试样的拉伸强度和弹性模量值显示出相似的结果。与其他打印方向相比，在XZ方向上打印显示出较差的强度值。完成了不同过渡方式的界面分析，并获得了梯度过渡的优势。分析了标本的显微照片以研究其内部结构，并用于验证测试结果。应用统计方法研究微观结构描述符（体积分数）与过程相关参数（印刷温度）之间的关系。方差分析（ANOVA）的结果证实，印刷温度和浓度对拉伸试验结果有重大影响。数据驱动的方法用于构建线性回归模型，以便为有限元分析（FEA）制定输入数据。FEA仿真的结果是，使用MATLAB代码计算了有效的杨氏模量。通过实验测试结果验证了FEA预测的杨氏模量。数值方法和实验值的比较表明，在250、260和270°C的温度下打印的FGM样品的误差小于5％。通过局部改变材料特性，采用FGM的FFF工艺可能在医疗，结构和汽车行业具有潜在的应用。这项研究提出了一种以低成本制造工艺制造FGM结构的独特方法。