Structural health monitoring of 3D printed structures

3D printed parts are used in industry for both tooling application and smaller parts in assembled structures. Articles made through polymer based additive manufacturing are anisotropic and may have defects throughout the part. For instance, the layer to layer interactions are weaker than the in-plane printing which can cause delamination of the layers. Identifying when and where the cracks form can be very difficult if the cracks are inside the structure This paper introduces an innovative patent-pending method to monitor polymer-based 3D printed structures for internal failures by printing a highly sensitive conductive material into the part itself. When a section of the conductive material inside the part is damaged or split, the resistance across the conductive pathway increases which will indicate that the article has been damaged. We present several small printed circuits and observations that show as a crack is introduced to the structure, the resistance measured increases which alerts users that a crack has formed/propagated.