Flexibility, toughness, and load bearing of 3D-printed chiral kerf composite structures

Abstract

Chiral kerf structures are formed by arranging chiral and coiled unit cells which allows for multi-dimensional and multi-scale shape configurations under mechanical loadings. In this study, we investigate how the mechanical properties of materials and microstructural topologies interact to control the flexibility, toughness, and load bearing of 3D-printed chiral kerf structures. We explore chiral kerf structures with two different kerf patterns, i.e., square and hexagon, and three coiling densities. We consider three materials, namely brittle Polylactic Acid (PLA), compliant thermoplastic polyurethane (TPU), and a ductile composite made by alternating PLA and TPU, referred to as a programmable composite. The chiral kerf structures undergo two deformation mechanisms when subjected to mechanical loadings. The first one results from reconfigurations of kerf cells such as uncoiling, rotation of cells, and cell packing, and the second mechanism arises from nonlinear and inelastic material responses. The use of brittle material limits cell reconfigurations before material failure, reducing the overall flexibility and toughness of kerf structures. While the compliant material enables full cell reconfigurations, it results in low load bearing. The use of PLA:TPU composite allows for cell reconfigurations and inelastic material response, enhancing flexibility and toughness while maintaining a relatively high load bearing. We demonstrate that stress distribution in kerf structures can be controlled by using multiple materials or coil densities. This strategy can delay failure and improve the toughness and load-bearing capabilities of kerf structures.