Investigation of the Mechanical Performance of Nature Inspired Lattice Metamaterials Manufactured by Fused Deposition Modeling

  • Saif Khalfan Al Marzooqi

Student thesis: Master's Thesis

Abstract

Lattice structures are three dimensional structures that consist of a repeating pattern of a unit cell and can be found in nature such as a honeycomb structure which is used extensively in the aviation industry. Additively manufactured lattice structures suffer from the use of support material that is used to create the lattice structures but are not a design component of the structure itself. They increase material consumption and manufacturing time and thus reduce the overall advantage of using additively manufactured lattice structures. Hence, the need to investigate the mechanical performance of a nature inspired lattice structure design using additive manufacturing without the use of support material. In this thesis, experimental and computational investigations were carried out to design, fabricate and test a nature inspired lattice structured material for energy absorption, using fused deposition modeling of Acrylonitrile Butadiene Styrene (ABS) material. The yield stress and strain to fracture of the material were optimized by varying the printing speed and extruder temperature set by the Intamsys Funmat Pro 410 H 3D printer using design of experiments (DOE). Once the optimum printing conditions were determined at 40 mm/s for printing speed and 260°C for extruder temperature, the design of experiments process is repeated to investigate the specific energy absorption of a supportless lattice structure for different sizes and relative densities under compression. The optimum design was compared with ANSYS finite element analysis software were the material constitutive model was created from the tensile testing experiment done earlier. The compression experiments showed that energy absorption per unit mass increased with increasing relative density and decreased lattice structure size at an optimum unit cell size of 10 mm and relative density of 0.4. Moreover, the ANSYS simulation showed resemblance in the elastic region when compared to the experimental compression of the supportless lattice structure.
Date of AwardApr 2022
Original languageAmerican English

Keywords

  • polymers
  • lattice structure
  • finite element analysis
  • additivemanufacturing.

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