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In this research, experimental and numerical methods were used to study the effect of pore geometry on residual stress and mechanical behavior of 3D-printed parts. In this regard, samples with circular, rhombic and hexagonal pore geometries were printed using fused deposition modeling (FDM), and their residual stress was measured through the mechanical strain release method. The finite-element method (FEM) was utilized to study the strength and natural frequency of the samples.

As a modern method of part manufacturing and repair, 3D printing has been highly regarded in industrial arenas for its ability to offer high precision without the need for different dies. Porosity has been studied as a solution for reducing weight in structures, and its effect on the mechanical behavior of a structure depends on the loading conditions and applications.

The results of the investigation showed that the rhombic pore geometry had the highest residual stress, while the sample with circular pores exhibited the lowest residual stress. Stress distribution and modal analyses indicated that the sample with rhombic pore geometry had the lowest displacement coupled with the highest strength and natural frequency. However, considering the total of external load-induced stress and residual stresses, the sample with hexagonal pore geometry outperformed the other samples and showed the longest fatigue life.

According to the literature review, residual stress is one of the key factors influencing the performance of 3D-printed parts. However, the effects of pore geometry on residual stress and structural strength in 3D-printed components remain underexplored. Therefore, this study investigates the impact of hexagonal, rhombic and circular pore geometries on residual stress and structural strength through both experimental and numerical analyses.