Enhancing Mechanical Energy Absorption of Honeycomb and Triply Periodic Minimal Surface Lattice Structures Produced by Fused Deposition Modelling in Reusable Polymers
Abstract
:1. Introduction
2. Materials and Methods
2.1. Lattice Structures
2.2. Material Properties and 3D Printing Parameters
2.3. Uniaxial Tensile and Compression Tests
2.4. Finite Element Analysis (FEA)
2.5. The 3D Printing of Lattice Structures
2.6. Energy Absorption Parameters
3. Results and Discussion
3.1. Mechanical Properties and Analysis
3.2. Redesign of the Unit Cells
3.3. Engineering Applications
4. Conclusions
- The tests carried out on these structures were designed to evaluate their ability to withstand repetitive compressive forces while maintaining structural integrity and reusability. It was demonstrated that material selection played a crucial role in both energy absorption capacity and reusability.
- TPC exhibited the highest initial energy absorption values, with 76.7 kJ observed for the Hex-Pomelo honeycomb structure and 30.3 kJ for the FRD334 TPMS structure. However, a significant degradation in material performance was observed after three repeated compression cycles, indicating a lower reusability potential.
- In contrast, PEBA, although initially absorbing slightly less energy initially, maintained its absorption efficiency over multiple cycles. Specifically, the FRD334 structure made from PEBA retained an energy absorption efficiency of 56.1% after three compressions, making it the most viable candidate for applications requiring reusability.
- Modifying the z-axis parameter in TPMS structures can significantly enhance their energy absorption capabilities. The FRD334 structure, designed with an even-numbered z-axis configuration, consistently outperformed other TPMS structures, including FRD222 and FRD223, in terms of energy absorption and SEA coefficient. The highest SEA coefficient for a 3D structure was recorded for FRD334 made of TPC (2.02 J/g).
- Even-numbered z-axis structures are more effective in terms of energy absorption performance because they allow for complete unit cell formation, thereby ensuring uniform energy distribution during compression. In contrast, odd-numbered z-axis structures incorporate an incomplete final cell row, resulting in diminished absorption performance.
- From a manufacturing perspective, it was revealed that the precision of the 3D printing process affected the mechanical behaviour of energy-absorbing structures. TPC showed superior print quality while TPU demonstrated the lowest print quality due to excessive mass accumulation from residual printing material.
- Two-dimensional honeycomb structures exhibited high initial energy absorption values but degraded more rapidly after repeated compressions. In contrast, TPMS structures, particularly the FRD334 architecture, demonstrated greater consistency in their performance across multiple compressions, highlighting their suitability for reusable energy absorption systems.
- The energy absorption efficiency remained stable in PEBA-based structures, with minimal degradation between compression cycles, supporting their potential use in safety equipment, automotive crash components, and aerospace impact protection systems. This consistent performance highlights their suitability for environments where repeatability is critical.
Author Contributions
Funding
Institutional Review Board Statement
Data Availability Statement
Conflicts of Interest
References
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Parameter | TPU 95A | TPC | PEBA |
---|---|---|---|
Printing Speed | 30 mm/s | 30 mm/s | 30 mm/s |
Max. Acceleration | 300 mm/s2 | 300 mm/s2 | 300 mm/s2 |
Nozzle Temperature | 230 °C | 230 °C | 240 °C |
Platform Temperature | 35 °C | 35 °C | 75 °C |
Fan Speed | 100% | 100% | 50% |
EPEBA (MPa) | ETPC (MPa) | ETPU (MPa) |
---|---|---|
32.62 ± 0.97 | 49.69 ± 0.7 | 14.49 ± 0.9 |
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Bustihan, A.; Botiz, I.; Branco, R.; Martins, R.F. Enhancing Mechanical Energy Absorption of Honeycomb and Triply Periodic Minimal Surface Lattice Structures Produced by Fused Deposition Modelling in Reusable Polymers. Polymers 2025, 17, 1111. https://doi.org/10.3390/polym17081111
Bustihan A, Botiz I, Branco R, Martins RF. Enhancing Mechanical Energy Absorption of Honeycomb and Triply Periodic Minimal Surface Lattice Structures Produced by Fused Deposition Modelling in Reusable Polymers. Polymers. 2025; 17(8):1111. https://doi.org/10.3390/polym17081111
Chicago/Turabian StyleBustihan, Alin, Ioan Botiz, Ricardo Branco, and Rui F. Martins. 2025. "Enhancing Mechanical Energy Absorption of Honeycomb and Triply Periodic Minimal Surface Lattice Structures Produced by Fused Deposition Modelling in Reusable Polymers" Polymers 17, no. 8: 1111. https://doi.org/10.3390/polym17081111
APA StyleBustihan, A., Botiz, I., Branco, R., & Martins, R. F. (2025). Enhancing Mechanical Energy Absorption of Honeycomb and Triply Periodic Minimal Surface Lattice Structures Produced by Fused Deposition Modelling in Reusable Polymers. Polymers, 17(8), 1111. https://doi.org/10.3390/polym17081111