Session: 01-04-01: Advances in Aerospace Structures

Paper Number: 121190

121190 - Flexural Strength and Shear Properties of Sandwich Composites Made of 3D-Printed Cores 

Sandwich composites have gained significant attention in sustainable energy industries due to their exceptional strength-to-weight ratio, bending-stiffness-to-weight ratio, and versatility in applications. Due to the increased demand for new materials with better durability under higher dynamic load and reduced density, the development of new sandwich composites and the investigation of their flexural and shear properties gained huge scientific interest. This study explores the utilization of 3D printed Acrylonitrile Butadiene Styrene (ABS) thermoplastic cores in sandwich composite to improve their flexural and shear strength properties. The research aims to develop new sandwich composites having lightweight yet robust material properties using additive manufacturing (AM) process and vacuum-assisted resin infusion technology.

The research methodology involves the fabrication of sandwich composites using ABS thermoplastic cores through a combination of fused deposition modeling (FDM) 3D printing technique and vacuum-assisted resin infusion process, a traditional composite manufacturing technique with a combination of epoxy resin and glass fiber reinforcement. These composites are characterized by their unique layering structure, with an ABS core sandwiched between two layers of composite skins. To evaluate the flexural and shear strength of the sandwich composites, a comprehensive set of mechanical tests is conducted considering ASTM standard sample specimens. Three-point bending tests are employed to assess the flexural properties, while in-plane shear tests are performed to analyze the shear strength. The results are compared with those of traditional sandwich composites with balsa and PET foam cores.

The findings demonstrate that sandwich composites with 3D-printed ABS thermoplastic cores exhibit significantly improved flexural and shear strength compared to foam-cored composites. The ABS thermoplastic cores exhibit excellent load-bearing capabilities, while the composite skins provide the necessary stiffness and reinforcement. This combination results in superior structural performance. Moreover, the 3D printing process allows for precise customization of the core's internal structure, enabling tailored mechanical properties. By adjusting the infill density and orientation during 3D printing, it is possible to optimize the core's mechanical properties to suit specific application requirements. This flexibility in core design offers a competitive advantage over conventional sandwich composite materials.

Additionally, the research explores the influence of various parameters, such as the infill density, infill pattern, and printing orientation, on the mechanical performance of the ABS thermoplastic cores. Finite element analysis (FEA) is employed to simulate and analyze the stress distribution within the cores under different loading conditions. This computational approach aids in optimizing the core design for enhanced mechanical properties.

In conclusion, this research offers valuable insights into the development of high-performance sandwich composites using 3D-printed ABS thermoplastic cores. The results indicate that these composites exhibit superior flexural and shear strength properties compared to traditional foam-cored composites, making them a promising choice for lightweight, yet robust structural applications. The ability to customize the internal structure of the thermoplastic cores through 3D printing provides a versatile approach for tailoring material properties to meet specific engineering needs. This innovative approach has the potential to revolutionize the design and manufacturing of lightweight, high-strength composite structures across various industries

Presenting Author: Gazi Abu Raihan University of New Orleans

Presenting Author Biography: Gazi Raihan is a graduate student who is doing his Ph.D. in Mechanical Engineering at the University of New Orleans. Currently, he is working under Dr. Uttam Chakravarty, Associate professor, the Department of Mechanical Engineering at the University of New Orleans. His current research focuses on investigating the prospective application of auxetic mechanical metamaterial for designing advanced wind blades and microelectromechanical devices.