Fabrication of polymeric lattice structures for optimum energy absorption using Multi Jet Fusion technology

• Published in: Materials & design 2018-10, Vol.155, p.86-98
• Main Authors: Habib, F.N., Iovenitti, P., Masood, S.H., Nikzad, M.
• Format: Article
• Language: English
• Subjects: 3D printing; Cell topology; Energy absorption; Finite element analysis; Lattice structure; Multi Jet Fusion
• ISSN: 0264-1275; 1873-4197
• DOI: 10.1016/j.matdes.2018.05.059

Unlike stochastic foams, 3D printed lattice structures can be created with a tailored microstructure to achieve the desired global mechanical properties. In this study, quasi-static energy absorption of six polymeric lattice structures of different unit cell topologies and deformation behaviours but with identical relative density are investigated. For the first time, a recently developed powerful 3D printing technology, namely Multi Jet Fusion (MJF), is utilized to produce high quality and performance lattices. Nonlinear finite element analysis (FEA) is used to analyse their compressive response and energy-absorbing characteristics. To validate the FEA results, experimental compression tests are performed on two types of lattices. The results of this investigation showed that the global energy absorption of lattices can be improved through controlling and manipulating their micro-topology. It is found that the lattice structures with bending-dominated deformation have low stiffness and strength but provide good energy absorption capability. The stretch and buckling dominated structures are shown to be stiffer and stronger but have low energy absorption performance. The findings of this research identify high performing unit cell geometries that can be used for energy absorption application of lattice structures in the development of advanced 3D printed structures that are superior to stochastic foams. [Display omitted] •Designing polymeric periodic lattice structures of identical relative density from six different unit cells•Successful fabrication of the lattices via Multi Jet Fusion (MJF)•Characterization of their quasi-static energy absorption behaviour using FEA and experimental validation•The lattice of octagonal unit cell provides the optimum energy absorption characteristics.•MJF can produce polymeric lattices of much better quality with dramatically reduced time than traditional FDM.