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3D printing-empowered lightweight lattice structure for energy absorption in compression behavior
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DOI：10.1088/1361-665X/ae6494.png)
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Abstract
En 中文
Lightweight lattice structures with high energy absorption and compressive stability are of great significance for advanced engineering applications. In this study, a hollow cylindrical cross-plate wall (HCC-PW) lattice structure is proposed to enhance axial crushing performance through topology optimization. Finite element simulations and quasi-static compression experiments were combined to investigate the deformation mechanism and compressive response of 3D-printed short carbon-fiber-reinforced thermoplastic lattice structures. Simulation results show that the HCC-PW structure exhibits lower stress dispersion, a more uniform stress field, and a clearer primary load-transfer path than the conventional thin-plate integrated hollow-strut lattice, thereby enabling more stable progressive deformation under axial compression. Experimental results further demonstrate that HCC-PW delivers the most balanced crushing response among the tested topologies, combining the highest mean crushing force, competitive specific energy absorption, and the highest energy crushing force efficiency over an extended strain range. The effects of material configuration were further examined using single-material, dual-material, and tri-material combinations of PETG-CF, PLA-CF, and ABS-CF. Among the multi-material configurations, PETG-CF/PLA-CF exhibited the most effective structural-material synergy, showing higher initial stiffness and a more stable post-peak response. In contrast, the tri-material configuration showed reduced load-bearing capacity due to premature interfacial damage. These results indicate that the configuration-optimized HCC-PW design provides an effective strategy to balance compressive stability and energy absorption in 3D-printed lightweight lattice structures.
Keywords:
multi-material
3D printing
lattice structure
energy absorption
compression behavior
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