Mechanical Performance and Failure Analysis of a 3D-Printed "Continuous Layer-Lattice Layer-Continuous Layer"...

Area of Science:

• Materials Science
• Mechanical Engineering
• Composite Materials

Background:

• Sandwich structures combine strong continuous layers with lightweight lattice cores for enhanced performance.
• Polymer matrix composite sandwich structures are underutilized due to limited performance data.
• Applications span weight-critical fields like aerospace, automotive, and robotics.

Purpose of the Study:

• To investigate the mechanical properties of novel polymer composite sandwich structures.
• To explore the impact of lattice design and fiber reinforcement on performance.
• To provide essential data for the broader application of these composite structures.

Main Methods:

• Additive manufacturing of sandwich structures with continuous long glass fiber (CGF) and short carbon fiber/polyamide (SCF/N) composite lattices.
• Systematic analysis of bi-directional tension/compression performance, failure modes, and mechanisms.
• Investigation of geometric feature effects on three-point bending properties.

Main Results:

• Sandwich structures demonstrated up to 54.3% greater bending resistance per unit weight compared to pure SCF/N.
• Weight reduction of 49% was achieved.
• Bending flexibility before fracture increased by 44%.

Conclusions:

• The developed sandwich structures offer significant improvements in weight, strength, and flexibility.
• These findings provide fundamental data supporting the use of fiber-reinforced polymer matrix composites in advanced engineering.
• Optimized lattice designs and material combinations are key to unlocking the potential of these structures.