Energy absorbing capability of additive manufactured multi-material honeycomb structure

Abstract

Purpose The present work aims in presenting the energy absorbing capability of different combination stacking of multiple materials, namely, Vero White and Tango Plus, under static and dynamic loading conditions. Design/methodology/approach Honeycomb structures with various multi-material stackings are fabricated using PolyJet 3D printing technique. From the static and dynamic test results, the structure having the better energy absorbing capability is identified. Findings It is found that from the various stacking combinations of multiple materials, the five-layered (5L) sandwich multi-material honeycomb structure has better energy absorbing capability. Practical implications This multi-material combination with a honeycomb structure can be used in the application of crash resistance components such as helmet, knee guard, car bumper, etc. Originality/value Through experimental work, various multi-material honeycomb structures and impact resistance of single material clearly indicated the inability to absorb impact loads which experiences a maximum force of 5,055.24 N, whereas the 5L sandwich multi-material honeycomb structure experiences a minimum force of 1,948.17 N, which is 38.5 per cent of the force experienced by the single material. Moreover, in the case of compressive resistance, 2L sandwich multi-material honeycomb structure experiences a maximum force of 5,887.5 N, whereas 5L sandwich multi-material honeycomb structure experiences a minimum force of 2,410 N, which is 40.9 per cent of the force experienced by two-layered (2L) sandwich multi-material honeycomb structure. In this study, the multi-material absorbed most of the input energy and experienced minimum force in both compressive and impact loads, thus showing its energy absorbing capability and hence its utility for structures that experience impact and compressive loads. A maximum force is required to deform the single and 2L material in terms of impact and compressive load, respectively, under maximum stiffness conditions.

Innovative Process Strategies in Powder-Based Multi-Material Additive Manufacturing

“…Choi et al [40] developed a rotating vat system to combine different thermosets in laser-based vat photopolymerization. Bartlett et al [42] and Boopathy et al [43] demonstrated the utilization of hard/soft structures by combining different UV-curable thermosets in a broad range of stiffnesses with MultiJet modeling for robotic applications. Also, Moore and Williams [44] et al investigated the fatigue properties of thermoset multi-material parts created through MultiJet modeling.…”

Use of shear thickening fluids in sport protection applications: a review

“…Boopathy et al explored the energy-absorbing potential of Vero White and Tango + material combinations under static and dynamic loads using PolyJet 3D printing to create various honeycomb structures (Rajendra Boopathy et al, 2019). They found that a five-layered (5L) sandwich multi-material honeycomb outperformed single materials in absorbing impact loads, with a minimum force of 1,948.17 N compared to 5,055.24 N of single materials (Rajendra Boopathy et al, 2019). These results suggest promising applications for these systems in improving the crash resistance of safety components like helmets, knee guards, and car bumpers.…”

Influence of Post-Processing on the Properties of Multi-Material Parts Obtained by Material Projection AM

“…This characteristic undoubtedly makes this technique stand out within additive manufacturing due to the simplification of the design in terms of reducing the number of components, as it allows different materials with different properties to be combined in the same part. With regard to the combination of materials, Boopathy et al [36] studied the energy absorption capacity of printed parts against impact, observing that the different combinations of materials and the direction of the load played an important role in the behavior of the composite material.…”