Abstract

Additive manufacturing of metamaterial composites allows for lightweight structures with tunable mechanical and functional properties. This study achieves this using a Hybrid fused filament fabrication process where PU foam is injected inside the supportless closed cell lattice structure made of thermoplastic polyurethane (TPU). The process is based on the direct digital manufacturing concept, eliminating the need for post-processing. The resulting structures exhibited improved mechanical properties, including stiffness, energy dissipation, and damping capacity. Functionally grading the lattice structures further enhanced their properties, making them highly customizable for energy-absorbing and damping products such as protective and sporting goods.

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