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Enhanced Energy Absorption and Flexural Performance of 3D Printed Sandwich Panels Using Slicer-Generated Interlocking

Amged Elhassan1, Hour Alhefeiti1, Mdimouna Al Karbi1

  • 1Mechanical and Aerospace Engineering Department, UAE University, Al Ain 15551, United Arab Emirates.

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|January 10, 2026
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Summary

This study enhanced 3D printed sandwich panels using slicer-made interlocking joints, significantly improving peak load, deflection, and energy absorption. The PET/TPU interlocked design showed the best energy absorption and peak load performance.

Keywords:
3D printingcompositeflexuralinterlocksandwich

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Area of Science:

  • Materials Science
  • Mechanical Engineering
  • Additive Manufacturing

Background:

  • 3D printed sandwich panels offer lightweight structural solutions.
  • Optimizing the interface between core and skin materials is crucial for performance.
  • Fused filament fabrication (FFF) is a common additive manufacturing technique.

Purpose of the Study:

  • To evaluate the impact of slicer-generated interlocking joints on the flexural properties and energy absorption of 3D printed sandwich panels.
  • To compare the performance of different infill topologies and skin/core material combinations.
  • To identify optimal designs for enhanced load capacity and damage tolerance.

Main Methods:

  • Three-point bending tests were conducted on FFF-manufactured sandwich panels with various infill topologies (Cross-3D, Grid, Gyroid, Line, Honeycomb) and skin/core materials (PA/TPU, PLA/TPU, PET/TPU).
  • Interlocking joints were introduced at the face-core interface using slicer software.
  • Flexural properties, peak load, maximum deflection, and energy absorption were measured and compared.

Main Results:

  • Interlocking joints increased peak load by up to 15%, maximum deflection by 48%, and energy absorption by 51% compared to non-interlocked designs.
  • The PET/TPU interlocked composite exhibited the highest energy absorption (2.45 J/mm³) and peak load (272.6 N).
  • The PA/TPU interlocked composite demonstrated superior flexibility and ductility with a mid-span deformation of 21.34 mm.

Conclusions:

  • Slicer-generated interlocking interfaces significantly enhance the load-bearing capacity and energy dissipation of additively manufactured sandwich beams.
  • The choice of skin and core materials, along with infill topology, critically influences the mechanical response.
  • These findings support the development of lightweight, damage-tolerant designs for structural applications using additive manufacturing.