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

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.