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<p>Additive manufacturing (3D printing) is used to fabricate the complex and customized parts for advanced engineering applications; however, there remains a limited comparative understanding of how different 3D printed parts (core geometries) with the combination of other polymer matrix material (sandwich composite structures) influence under different loading conditions. To address this gap, the present study investigates the mechanical behaviour of sandwich structures incorporating hexagonal, triangular, and tri-hexagonal cores under low velocity impact (LVI) and compression after impact (CAI) loading conditions. The cores were fabricated from polylactic acid (PLA) with a 10% infill density, while glass fibre reinforced polymer (GFRP) was used as the face sheet material, bonded using epoxy YD-128. Experimental evaluation was conducted through drop weight impact tests at approximately 10&#xa0;J and 20&#xa0;J at two critical locations, namely interaction of ribs and centre of cellular structure, followed by CAI testing to assess residual compressive strength. In addition, finite element simulations using Abaqus were performed to analyze stress distribution, energy absorption, and damage evolution. The results indicate that energy absorption, crack propagation, indentation depth, and damage modes are strongly dependent on core geometry. Among all configurations, the tri-hexagonal structure consistently demonstrated superior performance, exhibiting the highest energy absorption (≈9–14% higher than hexagonal and ≈35–44% higher than triangular), improved damage resistance, and minimal back face damage under both conditions. Whereas, The force displacement analysis under CAI indicates that the tri-hexagonal structure achieves ~ 20–30% higher peak force and ~ 25–40% greater displacement capacity as compared to the hexagonal structure, and ~ 50–80% higher peak force than the triangular structure, which demonstrating superior energy absorption and structural stability, while the triangular structure shows the lowest performance with early failure. The numerical simulations showed strong agreement with experimental observations, confirming that the tri-hexagonal geometry provides enhanced impact resistance through efficient stress distribution and multiple load transfer paths.</p>

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Comparative analysis of 3D printed core geometries effects on low velocity impact and CAI behaviour with GFRP as facesheets

  • 期刊论文

  • 发表日期：

    2026年5月1日

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  • Muhammad Azeem,
  • Muhammad Ali Nasir,
  • Owaisur Rahman Shah,
  • Aamir Mubashar,
  • Aneela Wakeel,
  • Lida Shen,
  • Riffat Asim Pasha

摘要

Additive manufacturing (3D printing) is used to fabricate the complex and customized parts for advanced engineering applications; however, there remains a limited comparative understanding of how different 3D printed parts (core geometries) with the combination of other polymer matrix material (sandwich composite structures) influence under different loading conditions. To address this gap, the present study investigates the mechanical behaviour of sandwich structures incorporating hexagonal, triangular, and tri-hexagonal cores under low velocity impact (LVI) and compression after impact (CAI) loading conditions. The cores were fabricated from polylactic acid (PLA) with a 10% infill density, while glass fibre reinforced polymer (GFRP) was used as the face sheet material, bonded using epoxy YD-128. Experimental evaluation was conducted through drop weight impact tests at approximately 10 J and 20 J at two critical locations, namely interaction of ribs and centre of cellular structure, followed by CAI testing to assess residual compressive strength. In addition, finite element simulations using Abaqus were performed to analyze stress distribution, energy absorption, and damage evolution. The results indicate that energy absorption, crack propagation, indentation depth, and damage modes are strongly dependent on core geometry. Among all configurations, the tri-hexagonal structure consistently demonstrated superior performance, exhibiting the highest energy absorption (≈9–14% higher than hexagonal and ≈35–44% higher than triangular), improved damage resistance, and minimal back face damage under both conditions. Whereas, The force displacement analysis under CAI indicates that the tri-hexagonal structure achieves ~ 20–30% higher peak force and ~ 25–40% greater displacement capacity as compared to the hexagonal structure, and ~ 50–80% higher peak force than the triangular structure, which demonstrating superior energy absorption and structural stability, while the triangular structure shows the lowest performance with early failure. The numerical simulations showed strong agreement with experimental observations, confirming that the tri-hexagonal geometry provides enhanced impact resistance through efficient stress distribution and multiple load transfer paths.