Experiments and Modeling of Three-Dimensionally Printed Sandwich Composite Based on ULTEM 9085

Area of Science:

• Materials Science
• Mechanical Engineering
• Additive Manufacturing

Background:

• ULTEM 9085 is a high-performance, but expensive, thermoplastic.
• Polycarbonate (PC) is a more cost-effective alternative with different mechanical properties.
• Sandwich composites offer a way to combine material properties and manage costs.

Purpose of the Study:

• To develop and characterize a novel ULTEM-PC-ULTEM sandwich composite.
• To investigate the feasibility of using fused filament fabrication (FFF) for creating this composite.
• To validate modeling techniques against experimental data for predicting mechanical behavior.

Main Methods:

• Three-dimensional (3D) printing of ULTEM 9085 and polycarbonate layers using FFF technology.
• Fabrication of ULTEM-PC-ULTEM sandwich composite specimens conforming to ISO 527-4 standards.
• Experimental testing including tensile and three-point bending tests.
• Development and application of simplified structural modeling using averaged stiffness and Classical Laminate Theory (CLT).

Main Results:

• Experimental data from tensile and bending tests were used to calibrate the predictive models.
• Simulated results showed good agreement with experimental findings, confirming model accuracy.
• The 3D-printed ULTEM-PC-ULTEM composite demonstrated favorable mechanical properties.

Conclusions:

• The ULTEM-PC-ULTEM sandwich composite is a viable material for engineering applications.
• FFF technology allows for flexible design and fabrication of these composites.
• This composite offers a cost-effective solution without significant compromise on performance.