Abstract
In this paper, a new process of joining additive manufactured (AM) lattice structures and carbon fiber-reinforced plastics (CFRPs) to manufacture hybrid lattice sandwich structures without secondary bonding is investigated. Multiple variations of lattice structures are designed and 3D printed using Digital Light Synthesis (DLS) and a two-stage (B-stage) epoxy resin system. The resulting lattice structures are only partially cured and subsequently thermally co-cured with pre-impregnated carbon fiber reinforcement. The mechanical properties of the additive manufactured lattice structures are characterized by compressive tests. Furthermore, the mechanical properties of hybrid lattice sandwich structures are assessed by flexural beam testing. From compressive testing of the additive manufactured lattice structures, high specific strength can be ascertained. The mechanical behavior shows these lattice structures to be suitable for use as sandwich core materials. Flexural beam testing of hybrid lattice sandwich structures shows high strength and stiffness. Furthermore, the strength of the co-cured bond interface is high enough to surpass the strength of the lattice core.
Highlights
An enduring challenge in modern mechanical engineering is the design of lightweight components which are strong and highly integrated, meaning they fulfill several tasks
Such structures are made up of a low-density core and facesheets manufactured from high specific strength fiber-reinforced polymers (FRP)
Due to the low density of the core material, this is accompanied by only a slight increase in mass
Summary
An enduring challenge in modern mechanical engineering is the design of lightweight components which are strong and highly integrated, meaning they fulfill several tasks. HHoowweevveerr,, tthhee ddeessiiggnn ffrreeeeddoomm ooff ssaannddwwiicchh ssttrruuccttuurreess iiss lliimmiitteedd,, aanndd mmaannuuffaaccttuurriinngg ccaann bbee ccuummbbeerrssoommee. Stretch-dominated structures show a pronounced peak in Segment I followed by post-yield softening in Segment II (Figure 2b) This indicates a high yield strength, with a high apparent stiffness. Due to these properties, such structures can be used for the lightweight design, including load bearing components or sandwich. Sci. 2019, 3, 53 show a pronounced peak in Segment I followed by post-yield softening in Segment II (Figure 2b) With the lattice design determined, two types of tests are performed: First, compressive testing of 3D-printed lattice structures without the fiber reinforcement, and second flexural testing of fully 3D-printed lattice sandwich structures and CFRP hybrid lattice sandwich structures
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