Additive manufacturing of biphasic architectured structure and analysis of its mechanical and functional response

This study introduces a new method for fabricating biphasic architectured structures using self-developed hybrid material extrusion (MEX) process. This approach involves filling the voids of closed-cell structures with a powder material in a single process. The architectured structures were 3D printed using thermoplastic polyurethane (TPU) and subsequently filled with polyamide 12 (PA12) powder in two distinct configurations: partially filled (50%) and fully filled (100%), named as biphasic architectured structures. Experimental and numerical uniaxial quasistatic compression tests were conducted on partially filled and fully filled local and global closed-cell architectured structures, and their results were compared with those of empty architectured structures. The comparative analysis revealed that the partially filled structures, representing a transitional phase, exhibit enhanced properties which is influenced by the amount of powder filling within the structure. A substantial enhancement in stiffness and specific energy absorption (SEA) was observed in the consolidation phase. The fully filled architectured structures exhibit rapid increase in its loading response, characterized by high stiffness and SEA. Furthermore, this study paves the way for future exploration into strategic filling of multiple powders in different regions, thereby tailoring the mechanical and functional responses. Potential applications include manufacturing components and equipment that absorb energy, provide impact protection, and offer vibration damping and soundproofing capabilities.