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<p>In multi-material additive manufacturing (AM), the structural strength and integrity are often limited by the intrinsic material compatibility, limiting the design flexibility and performance of the structures. In this work, a cellular structure-based mechanical interlocking (CMI) interface design concept is investigated for material extrusion AM, in order to establish preliminary design understanding of this concept. Multiple design variables, including cellular topology design, phase composition ratio and material assignment to individual phases, were investigated for their influences on the mechanical characteristics of the CMI designs. Experimental-based investigation was carried out, which was complemented by additional finite element simulations for qualitative understanding of the influence of structural coupling on local stress concentrations. The results showed that CMI interface designs could potentially achieve significant improvements on various mechanical properties such as tensile strength and volumetric energy absorption (~ 300% increase) when compared to flat interface benchmark, while these properties are also sensitive to various factors such as cellular topology, phase composition percentage ratio and baseline material property contrasts. Further, the property of the CMI could be tailored by topology design of the cellular structures, demonstrating potentials in its designability. Finally, it was found that the properties of the CMI are significantly impacted by printing setup, which was likely not optimized for this novel design concept and requires additional future research.</p>

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An experimental study of cellular mechanical interface in a bi-material structure fabricated by material extrusion additive manufacturing

  • 期刊论文

  • 发表日期：

    2026年5月6日

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  • Sumit Paul,
  • Li Yang

摘要

In multi-material additive manufacturing (AM), the structural strength and integrity are often limited by the intrinsic material compatibility, limiting the design flexibility and performance of the structures. In this work, a cellular structure-based mechanical interlocking (CMI) interface design concept is investigated for material extrusion AM, in order to establish preliminary design understanding of this concept. Multiple design variables, including cellular topology design, phase composition ratio and material assignment to individual phases, were investigated for their influences on the mechanical characteristics of the CMI designs. Experimental-based investigation was carried out, which was complemented by additional finite element simulations for qualitative understanding of the influence of structural coupling on local stress concentrations. The results showed that CMI interface designs could potentially achieve significant improvements on various mechanical properties such as tensile strength and volumetric energy absorption (~ 300% increase) when compared to flat interface benchmark, while these properties are also sensitive to various factors such as cellular topology, phase composition percentage ratio and baseline material property contrasts. Further, the property of the CMI could be tailored by topology design of the cellular structures, demonstrating potentials in its designability. Finally, it was found that the properties of the CMI are significantly impacted by printing setup, which was likely not optimized for this novel design concept and requires additional future research.