This study aims to comprehensively review previous and present research on the dynamic responses of 3D-printed sandwich composite structures. The low-velocity impact and failure mechanisms caused by the impact load and energy absorption capabilities are discussed. Investigating the processes and mechanics of a material is an essential step in addressing the structural failure problems, which are mostly caused by a fracture. The encouraging impact resistance results have prompted researchers to explore the capabilities of structural integrity to optimize performance, which can be accomplished leveraging the enhanced material and architectural combinations of sandwich composites. The ongoing research into low-velocity behavior of fabricated sandwich composite structures with 3D-printed hexagonal honeycomb cores and varying core materials is emphasized in this study.
Additive Manufacturing (AM) technology is extensively used in aeronautical applications, especially in designing the sandwich composite structures for repair tasks. However, the composite structures are vulnerable to impact loadings because of their exposure to, for instance, loading field carriages, flying debris, and bird strikes. This may lead to crack propagation and ultimately the structural failure. Therefore, it is important to investigate the mechanical behaviour of sandwich composite structures under low–velocity impact. In this research, carbon fiber fabric reinforced 3D–printed thermoplastic composite of hexagonal honeycomb cores structures were fabricated with different unit cells (6, 8, and 10 mm) and varying materials (Polylactic acid (PLA), PLA–Wood and PLA–Carbon). A drop weight impact test was performed under impact energies (5, 8, and 11 J) to determine the energy absorption performance of the structures whereas the surface morphology was analysed using a high–intensity optical microscope. Comparing unit cells of materials used, it is observed that the unit cell of 8 mm is the best configuration for lightweight materials with impressive energy absorption capabilities. Under an impact energy of 11 J, the PLA–Wood of unit cell 8 mm shows 9.22 J higher in energy absorption than unit cell 10 mm which is 7.44 J due to intermediate stiffness that resists further deformation. While the filled PLA shows the PLA–Wood material offers better performance in energy absorption capability compared to PLA–Carbon. The PLA–Wood demonstrates 9.22 J more energy absorption for an unit cell 8 mm under an impact energy of 11 J than the PLA–Carbon, which is 8.49 J. This is due to the good compatibility between the hydroxyl groups of the polymer matrix and lignocellulose filler, which translates to better stiffness.
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