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Programming Failure Mode Transitions in Polyurea-Reinforced 3D-Printed ABS and PA-GF Cellular Metamaterial

Rodrigo Valle1, César Garrido2, Víctor Tuninetti3

  • 1Construction Multidisciplinary Research Group, Facultad de Arquitectura, Construcción y Medio Ambiente, Universidad Autónoma de Chile, Talca 3460000, Chile.

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Summary

This study combines 3D printing lattice designs with polyurea infiltration to prevent brittle failure in cellular structures. The new composite materials transition from fragmentation to stable collapse, enhancing impact energy absorption.

Keywords:
Design for Additive Manufacturing (DfAM)architected cellular materialsfailure mode transitionhybrid prototypinginterpenetrating phase composites (IPC)

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Area of Science:

  • Materials Science
  • Mechanical Engineering
  • Additive Manufacturing

Background:

  • Additively manufactured cellular structures often fail brittlely under impact due to stress concentrations.
  • Controlling failure modes is crucial for enhancing energy absorption and damage tolerance.

Purpose of the Study:

  • To investigate the effect of combining lattice topology and hyperelastic polyurea infiltration on the mechanical response and failure modes of 3D-printed cellular composites.
  • To achieve active control over the transition from catastrophic fragmentation to stable progressive collapse.

Main Methods:

  • Fused Deposition Modeling (FDM) was used to print auxetic and honeycomb specimens with ABS and glass-fiber-reinforced polyamide (PA-GF).
  • Specimens were evaluated in unreinforced and polyurea-infiltrated states under quasi-static compression, three-point bending, and Charpy impact loading.

Main Results:

  • Cellular topology primarily influenced compressive response, with auxetic configurations showing highest stiffness and energy absorption.
  • Polyurea infiltration increased post-yield stability and elastic recovery, shifting failure modes from brittle to stable elastomeric deformation.
  • Polyurea infiltration increased absorbed impact energy by over 30% for PA-GF and 52% for ABS, preventing catastrophic failure.

Conclusions:

  • Integrating topological sequencing with elastomeric confinement offers a method to control energy dissipation and damage tolerance in 3D-printed cellular composites.
  • This approach enables the transition from brittle fragmentation to stable progressive collapse, enhancing material performance under impact.