Crashworthiness Investigations for 3D-Printed Multi-Layer Multi-Topology Engineering Resin Lattice Materials

Area of Science:

• Materials Science
• Mechanical Engineering
• Additive Manufacturing

Background:

• Cellular solids, particularly periodic lattice materials, exhibit superior energy absorption over monolithic materials.
• Additive manufacturing enables the creation of highly customizable and repeatable lattice structures.
• Crashworthiness is a critical performance metric for materials subjected to impact.

Purpose of the Study:

• To experimentally investigate the crashworthiness of multi-layer, multi-topology (MLMT) resin lattices.
• To compare the energy absorption capabilities of MLMT lattices with single-topology lattices.
• To evaluate the influence of layered and mixed topologies on lattice performance.

Main Methods:

• Fabrication of single-topology (cubic, octet) and multi-layer, multi-topology (MLMT) resin lattices using additive manufacturing.
• Experimental testing of lattice structures at a relative density of 30% to determine crashworthiness.
• Measurement of energy absorption up to the densification point for various lattice configurations.

Main Results:

• Three-layer single-topology cubic and octet lattices absorbed 9.8 J and 7.8 J, respectively.
• MLMT lattices demonstrated significantly higher energy absorption: 19.0 J (octet-cube-octet) and 22.4 J (cube-octet-cube).
• MLMT lattices achieved 94% to 187% greater energy absorption compared to single-topology lattices of equivalent mass.

Conclusions:

• MLMT lattice designs offer substantially improved energy absorption performance.
• The combination of multiple layers and distinct topologies enhances crashworthiness.
• These findings highlight the potential of MLMT lattices for advanced energy-absorbing applications.