Multi-material additive manufacturing with lightweight closed-cell foam-filled lattice structures for enhanced mechanical and functional properties

Prajapati, Mayur Jiyalal; Kumar, Ajeet; Lin, Shang-Chih; Jeng, Jeng-Ywan

doi:10.1016/j.addma.2022.102766

Cited by 34 publications

(25 citation statements)

References 29 publications

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“…The compressive behaviour of the open and thin-walled closed lattice structures was similar in terms of mechanical and functional properties; however, the performance metrics of the thick-walled results were 20% lower. This was in contrast with previous results obtained by the same authors for closed-cell lattice structures printed with PLA filaments, where the best response in terms of stiffness and energy absorption was obtained with a thin-walled structure compared to other geometries [ 14 ].…”

Section: Discussioncontrasting

confidence: 99%

“…The lattice structure was supportless based on generating a primitive surface patch in Matlab 2021b©. These surface geometries were exported in Creo Parametric© environment for converting them to solid by adding and trimming material in the outer direction for the final local closed-cell design, as shown in Figure 1 [ 14 , 26 ].…”

Section: Methodsmentioning

confidence: 99%

“…These two principles can be employed to produce both local and global closed-cell lattice structures [ 14 , 15 ]. Local closed-cell lattice structures have fully closed unit cells that are tessellated in the design space.…”

Section: Introductionmentioning

confidence: 99%

“…The impact of additive manufacturing and its material development is seen in various fields, such as photopolymerization of the polymer under visible light [ 18 , 19 ]. Additive manufacturing of thermoplastic polyurethane (TPU) material is increasingly used in industrial fields, such as footwear, automotive, and aerospace, owing to its biodegradable nature, abrasion resistance, flexibility, and energy absorption capability [ 13 , 14 ]. Printed TPU does not exhibit intuitive behaviour due to its hygroscopic, viscoelastic and hyperelastic nature [ 20 ].…”

Section: Introductionmentioning

confidence: 99%

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Energy Absorption and Stiffness of Thin and Thick-Walled Closed-Cell 3D-Printed Structures Fabricated from a Hyperelastic Soft Polymer

et al. 2022

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This study analyses the energy absorption and stiffness behaviour of 3D-printed supportless, closed-cell lattice structures. The unit cell design is bioinspired by the sea urchin morphology having organism-level biomimicry. This gives rise to an open-cell lattice structure that can be used to produce two different closed-cell structures by closing the openings with thin or thick walls, respectively. In the design phase, the focus is placed on obtaining the same relative density with all structures. The present study demonstrates that closure of the open-cell lattice structure enhances the mechanical properties without affecting the functional requirements. Thermoplastic polyurethane (TPU) is used to produce the structures via additive manufacturing (AM) using fused filament fabrication (FFF). Uniaxial compression tests are performed to understand the mechanical and functional properties of the structures. Numerical models are developed adopting an advanced material model aimed at studying the hysteretic behaviour of the hyperelastic polymer. The study strengthens design principles for closed-cell lattice structures, highlighting the fact that a thin membrane is the best morphology to enhance structural properties. The results of this study can be generalised and easily applied to applications where functional requirements are of key importance, such as in the production of lightweight midsole shoes.

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Section: Discussioncontrasting

confidence: 99%

Section: Methodsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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Energy Absorption and Stiffness of Thin and Thick-Walled Closed-Cell 3D-Printed Structures Fabricated from a Hyperelastic Soft Polymer

et al. 2022

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“…AM technologies such as Fused Filament Fabrication -FFF can produce multi-materials components in a single process [1]. FFF proved that it is suitable for manufacturing functional parts, sandwich panels [2], shapememory structures [1,3,4], medical applications [1], and others.…”

Section: Introductionmentioning

confidence: 99%

Influence of bond interface over the lap-shear performance of 3D printed multi-material samples

Ermolai

Raichur²,

Nagîţ³

2022

MATEC Web Conf.

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Multi-material 3D printing offers new possibilities regarding product development, allowing design freedom and multiple materials choices in terms of colour and polymer type. Material extrusion technologies are among the most popular options for multi-material printing due to their low equipment cost and various thermoplastic materials. However, polymers’ compatibility and bond interface must be considered for multi-material components. Material Extrusion creates the parts layer by layer, and each layer is characterised by multiple lines of extruded thermoplastic at a defined width. Therefore, regardless of the 3D model’s surfaces, they are composed of numerous lines of material and voids. Depending on the 3D Printing process setup, the bonding mechanism between materials can be influenced due to the different characteristics of horizontal and vertical contact interfaces. For this reason, this paper aims to study the influence of process parameters over horizontal interface through lap-shear tests for multimaterials samples made of acrylonitrile butadiene styrene (ABS), acrylonitrile styrene acrylate (ASA), and polycarbonate (PC). The results show that bond interface strength can be improved by creating ways for the mechanical interlock of the materials.

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Enhancement of Damping Characteristics through Hybridization: Investigating the Synergistic Effects of Triply Periodic Minimal Surface Additive Metals and Silicone Polymers

Ozden,

Simsek,

Ozdemir

et al. 2024

Adv Eng Mater

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Using TPMS metal parts with added silicone polymer can lead to the development of hybrid materials with enhanced damping characteristics. This study aims to develop composite structures by hybridizing additively manufactured TPMS metal parts with added silicone polymers for vibration applications. Central to this investigation is the quest to ascertain the most efficacious damping mechanism. In this context, the finite element method (FEM)‐based model of the primitive TPMS structure, consisting of Cobalt‐Chrome (CoCr) and the concomitant hybrid structure integrated with silicone polymer, was meticulously developed. The damping characteristics of the FEM‐based models were obtained by modal analysis. The models were also validated using experimental modal tests and their effectiveness in improving the damping characteristics of hybrid structures was confirmed. The findings show a significant improvement in damping characteristics thanks to the hybrid TPMS structure. Specifically, the damping ratios derived from the hybrid TPMS structure exhibit a sixfold increase in time‐domain damping and up to a thirty‐fold increase in frequency‐based analysis across two distinct damping calculation methodologies. In essence, this research unequivocally establishes the hybrid structure’s unparalleled damping capabilities, making it a vanguard in applications necessitating optimal vibration control. Overall, this study highlights the potential of additively fabricated primitive TPMS metal parts with added silicone polymer as a promising structure for improving damping properties in various engineering applications.This article is protected by copyright. All rights reserved.

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Multi-material additive manufacturing with lightweight closed-cell foam-filled lattice structures for enhanced mechanical and functional properties

Cited by 34 publications

References 29 publications

Energy Absorption and Stiffness of Thin and Thick-Walled Closed-Cell 3D-Printed Structures Fabricated from a Hyperelastic Soft Polymer

Energy Absorption and Stiffness of Thin and Thick-Walled Closed-Cell 3D-Printed Structures Fabricated from a Hyperelastic Soft Polymer

Influence of bond interface over the lap-shear performance of 3D printed multi-material samples

Enhancement of Damping Characteristics through Hybridization: Investigating the Synergistic Effects of Triply Periodic Minimal Surface Additive Metals and Silicone Polymers

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