Design and fabrication of carbon fiber lattices using 3D weaving

We present a method of designing and fabricating 3D carbon fiber lattices. The lattice design and fabrication is based on crocheting and sewing techniques, where carbon fiber tow is woven through two parallel carbon fiber grids and reinforced with vertical carbon fiber tubes. Compression testing is then performed on three different designs, and these results are compared to other similar lattice structures, finding that the lattices perform similarly to comparable lattices. Finite element analysis is also performed to validate the experimental findings, and provides some insight into the experimental results. The process presented here allows for more design flexibility than other current methods. For example, within a single lattice, different density weave patterns can be used to address specific load requirements. Though fabricated manually here, this process can also be automated for large scale production. With this design flexibility, simplified fabrication, and high strength, the lattices proposed here offer an advantage as compared to similar existing structures.