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<p>Selective laser sintering (SLS) technique has emerged as an important method in additive manufacturing, facilitating the manufacturability of complex lattice structures, known for their high stiffness-to-weight ratios. However, these structures face mechanical limitations, such as low compressive strength and energy absorption, restricting their use in demanding industries like aerospace and automotive. This study addressed these challenges by reinforcing SLS-printed Nylon 12 (polyamide 12, PA12) lattice structures with thermoset resins (bisphenol A, BPA epoxy), forming layered composites that significantly improved compressive and energy absorption performance. A continuous rotation coating technique was introduced to overcome the uneven reinforcement observed in traditional dip-coating method, achieving a uniform resin distribution. The optimized coating method resulted in a 13% improvement (61.22 to 69.18&#xa0;MPa) in compressive yield strength compared to dip-coated samples, contributing to an overall 139% increase (28.89 to 69.18&#xa0;MPa) relative to unreinforced PA12. Further enhancement was achieved through the incorporation of functionalized graphene nanofillers into the PA12/thermoset matrix, with the optimal configuration (68:32 PA12-to-BPA epoxy ratio with 0.1 wt% graphene) yielding a 201% increase (28.89 to 87.01&#xa0;MPa) in compressive yield strength and a 154% increase (366.26 to 928.56&#xa0;J/kg) in specific energy absorption. Image analysis of the cross-sections of struts from the tested lattice structures confirmed improved adhesion, and improved structural integrity at the samples with optimal configuration. Findings from this study can provide a pathway for industrial applications of SLS-printed lattice structures, enabling lightweight, high-strength components for aerospace and automotive industries.</p>

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Enhancing compressive properties of SLS-printed Nylon lattice structures using continuous-rotation thermoset coatings and graphene nanofillers

  • 期刊论文

  • 发表日期：

    2025年10月11日

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  • Aime Regis Rugerinyange,
  • Yingbin Hu,
  • Muhammad Pervej Jahan

摘要

Selective laser sintering (SLS) technique has emerged as an important method in additive manufacturing, facilitating the manufacturability of complex lattice structures, known for their high stiffness-to-weight ratios. However, these structures face mechanical limitations, such as low compressive strength and energy absorption, restricting their use in demanding industries like aerospace and automotive. This study addressed these challenges by reinforcing SLS-printed Nylon 12 (polyamide 12, PA12) lattice structures with thermoset resins (bisphenol A, BPA epoxy), forming layered composites that significantly improved compressive and energy absorption performance. A continuous rotation coating technique was introduced to overcome the uneven reinforcement observed in traditional dip-coating method, achieving a uniform resin distribution. The optimized coating method resulted in a 13% improvement (61.22 to 69.18 MPa) in compressive yield strength compared to dip-coated samples, contributing to an overall 139% increase (28.89 to 69.18 MPa) relative to unreinforced PA12. Further enhancement was achieved through the incorporation of functionalized graphene nanofillers into the PA12/thermoset matrix, with the optimal configuration (68:32 PA12-to-BPA epoxy ratio with 0.1 wt% graphene) yielding a 201% increase (28.89 to 87.01 MPa) in compressive yield strength and a 154% increase (366.26 to 928.56 J/kg) in specific energy absorption. Image analysis of the cross-sections of struts from the tested lattice structures confirmed improved adhesion, and improved structural integrity at the samples with optimal configuration. Findings from this study can provide a pathway for industrial applications of SLS-printed lattice structures, enabling lightweight, high-strength components for aerospace and automotive industries.