A platform for research: civil engineering, architecture and urbanism
A platform for research: civil engineering, architecture and urbanism
Lightweight hybrid composite sandwich structures with additively manufactured cellular cores
https://orcid.org/0000-0003-4196-7843
https://orcid.org/0000-0002-1407-6394
https://orcid.org/0000-0003-4140-1823
Abstract This study focuses on advancing sandwich structures by designing and fabricating complex two- and three-dimensional cellular cores combined with Carbon Fiber Reinforced Polymer (CFRP) skins. Numerical analysis is used to investigate the effect of core design and density on the bending performance. Optimal configurations are identified and experimentally validated. Professional Fused Filament Fabrication (FFF) equipment with a heating chamber is employed for manufacturing the core samples to enhance layer cohesion and material joint stiffness. A high-performance technical polymer with a superior strength-to-weight ratio is employed to maximize structural capabilities. Hybrid sandwich structures with PEI Ultem cellular cores demonstrate stiffness and strength comparable to reference materials, outperforming foam cores while slightly trailing behind Nomex® and aluminum honeycombs. In addition, the results demonstrate more efficient cell morphologies achievable through additive manufacturing technologies, surpassing the hexagonal design. This work provides valuable insights into hybrid composite materials and the potential of additive manufacturing in creating lightweight, high-performance sandwich panels.
Highlights AM enables efficient sandwich core designs, surpassing honeycomb structures. AM cellular cores outperform polyurethane foams in sandwich structures. TPMS designs printed with continuous deposition paths strengthens cell joints. Single-contour two-dimensional patterns offer superior weight reduction. Thinner walls and combined-material printers could provide more efficient designs.
Lightweight hybrid composite sandwich structures with additively manufactured cellular cores
https://orcid.org/0000-0003-4196-7843
https://orcid.org/0000-0002-1407-6394
https://orcid.org/0000-0003-4140-1823
Abstract This study focuses on advancing sandwich structures by designing and fabricating complex two- and three-dimensional cellular cores combined with Carbon Fiber Reinforced Polymer (CFRP) skins. Numerical analysis is used to investigate the effect of core design and density on the bending performance. Optimal configurations are identified and experimentally validated. Professional Fused Filament Fabrication (FFF) equipment with a heating chamber is employed for manufacturing the core samples to enhance layer cohesion and material joint stiffness. A high-performance technical polymer with a superior strength-to-weight ratio is employed to maximize structural capabilities. Hybrid sandwich structures with PEI Ultem cellular cores demonstrate stiffness and strength comparable to reference materials, outperforming foam cores while slightly trailing behind Nomex® and aluminum honeycombs. In addition, the results demonstrate more efficient cell morphologies achievable through additive manufacturing technologies, surpassing the hexagonal design. This work provides valuable insights into hybrid composite materials and the potential of additive manufacturing in creating lightweight, high-performance sandwich panels.
Highlights AM enables efficient sandwich core designs, surpassing honeycomb structures. AM cellular cores outperform polyurethane foams in sandwich structures. TPMS designs printed with continuous deposition paths strengthens cell joints. Single-contour two-dimensional patterns offer superior weight reduction. Thinner walls and combined-material printers could provide more efficient designs.
Lightweight hybrid composite sandwich structures with additively manufactured cellular cores
https://orcid.org/0000-0003-4196-7843
https://orcid.org/0000-0002-1407-6394
https://orcid.org/0000-0003-4140-1823
Abstract This study focuses on advancing sandwich structures by designing and fabricating complex two- and three-dimensional cellular cores combined with Carbon Fiber Reinforced Polymer (CFRP) skins. Numerical analysis is used to investigate the effect of core design and density on the bending performance. Optimal configurations are identified and experimentally validated. Professional Fused Filament Fabrication (FFF) equipment with a heating chamber is employed for manufacturing the core samples to enhance layer cohesion and material joint stiffness. A high-performance technical polymer with a superior strength-to-weight ratio is employed to maximize structural capabilities. Hybrid sandwich structures with PEI Ultem cellular cores demonstrate stiffness and strength comparable to reference materials, outperforming foam cores while slightly trailing behind Nomex® and aluminum honeycombs. In addition, the results demonstrate more efficient cell morphologies achievable through additive manufacturing technologies, surpassing the hexagonal design. This work provides valuable insights into hybrid composite materials and the potential of additive manufacturing in creating lightweight, high-performance sandwich panels.
Highlights AM enables efficient sandwich core designs, surpassing honeycomb structures. AM cellular cores outperform polyurethane foams in sandwich structures. TPMS designs printed with continuous deposition paths strengthens cell joints. Single-contour two-dimensional patterns offer superior weight reduction. Thinner walls and combined-material printers could provide more efficient designs.
Lightweight hybrid composite sandwich structures with additively manufactured cellular cores
Forés-Garriga, Albert (author) / Gómez-Gras, Giovanni (author) / Pérez, Marco A. (author)
Thin-Walled Structures ; 191
2023-08-02
Article (Journal)
Electronic Resource
English
| British Library Online Contents | 2018
Design and Manufacture of Monolithic Sandwich Structures with Cellular Cores
| British Library Conference Proceedings | 1998