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

This article presents the concept, research, and modeling of a sandwich composite made from ULTEM 9085 and polycarbonate (PC). ULTEM 9085 is relatively expensive compared to polycarbonate, and the composite structure made of these two materials allows for maintaining the physical properties of ULTEM while reducing the overall costs. The composite consisted of outer layers made of ULTEM 9085 and a core made of polycarbonate. Each layer was 3D-printed using the fused filament fabrication (FFF) technology, which enables nearly unlimited design flexibility. The geometry of the test specimens corresponds to the ISO 527-4 standard. Tensile and three-point bending tests were conducted. The structure was modeled in a simplified manner using averaged stiffness values, and with the classical laminate theory (CLT). The models were calibrated through tensile and bending tests on ULTEM and polycarbonate prints. The simulation results were compared with experimental data, demonstrating good accuracy. The 3D-printed ULTEM-PC-ULTEM composite exhibits favorable mechanical properties, making it a promising material for cost-effective engineering applications.