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Abstract <p>Triply periodic minimal surface (TPMS) lattices offer high structural efficiency for lightweight energy absorption, yet the effects of chopped fiber reinforcement and post-processing on their mechanical response remain poorly quantified. This study systematically investigates the mechanical behavior of additively manufactured gyroid TPMS lattices fabricated from five polymeric filaments—VeroWhite, Nylon 12, ABS, carbon fiber-reinforced PLA (PLA-CF) and polyphthalamide (PPA-CF)—across relative densities of 20–40%. Experimental results show that annealed fiber-reinforced lattices, particularly PPA-CF, consistently outperform unreinforced polymers in terms of peak stress, toughness, and energy absorption, with performance gains becoming more pronounced at higher relative densities. Post-print thermal annealing of PPA-CF increases its peak stress by <InlineEquation ID="IEq1"> <EquationSource Format="TEX">\(\sim 40\)</EquationSource> </InlineEquation>% and toughness by up to 60%, while altering its post-yield deformation stability. Annealed PPA-CF gyroids achieve specific energy absorption values of up to 24–25&#xa0;kJ/kg at densities of 200–430&#xa0;kg/m<sup>3</sup>, comparable to reported metallic TPMS structures, at substantially lower weight. Finite element analysis reveals elevated stress localization and increased plastic strains in fiber-reinforced lattices, consistent with the experimentally recorded post-elastic ductility trade-offs. These findings demonstrate that chopped fiber CF reinforcement, in combination with thermal post-processing, fundamentally modifies deformation behavior and enables high-performance, lightweight TPMS architectures through coordinated control of relative density and processing.</p> Graphical abstract <p></p>

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Do chopped fibers matter? Process–structure–property relationships and thermal annealing effects in fiber-reinforced TPMS lattices

  • 期刊论文

  • 发表日期：

    2026年7月10日

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  • Shahadat Hussain,
  • Haris Mehraj,
  • Mohamed Moustafa,
  • Nikolaos Karathanasopoulos

摘要

Abstract

Triply periodic minimal surface (TPMS) lattices offer high structural efficiency for lightweight energy absorption, yet the effects of chopped fiber reinforcement and post-processing on their mechanical response remain poorly quantified. This study systematically investigates the mechanical behavior of additively manufactured gyroid TPMS lattices fabricated from five polymeric filaments—VeroWhite, Nylon 12, ABS, carbon fiber-reinforced PLA (PLA-CF) and polyphthalamide (PPA-CF)—across relative densities of 20–40%. Experimental results show that annealed fiber-reinforced lattices, particularly PPA-CF, consistently outperform unreinforced polymers in terms of peak stress, toughness, and energy absorption, with performance gains becoming more pronounced at higher relative densities. Post-print thermal annealing of PPA-CF increases its peak stress by \(\sim 40\) % and toughness by up to 60%, while altering its post-yield deformation stability. Annealed PPA-CF gyroids achieve specific energy absorption values of up to 24–25 kJ/kg at densities of 200–430 kg/m3, comparable to reported metallic TPMS structures, at substantially lower weight. Finite element analysis reveals elevated stress localization and increased plastic strains in fiber-reinforced lattices, consistent with the experimentally recorded post-elastic ductility trade-offs. These findings demonstrate that chopped fiber CF reinforcement, in combination with thermal post-processing, fundamentally modifies deformation behavior and enables high-performance, lightweight TPMS architectures through coordinated control of relative density and processing.

Graphical abstract