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<p>Fused filament fabrication (FFF) using carbon fiber-reinforced polyamide (PA/CF) composites offers promising potential for lightweight structural components due to its ease of processing and environmental compatibility. However, there is still a lack of a thorough understanding of how various infill densities and patterns impact PA/CF composites’ mechanical and vibrational behavior. By examining the effects of cubic, gyroid, and honeycomb infill patterns at three infill densities (50%, 70%, and 90%) on mechanical strength, energy absorption, damping, and natural frequency, this study fills this knowledge gap. FFF was used to fabricate PA/CF specimens, which were then tested for tensile, flexural, impact, Shore D hardness, compression, and free vibration properties in accordance with ASTM guidelines. According to the results, Honeycomb continuously demonstrated the highest tensile modulus (~ 1.026 GPa) and impact strength (5.76&#xa0;kJ/m<sup>2</sup>), while the gyroid pattern at 90% infill achieved the highest tensile strength (38.41&#xa0;MPa). With a strength of 63.3&#xa0;MPa under flexural loading, cubic at 70% infill also demonstrated the highest damping ratio (0.103) and natural frequency (38.54&#xa0;Hz) in vibration analysis. To determine the optimal infill configuration, the COmplex PRoportional Assessment (COPRAS) multi-criteria decision-making method was employed. According to energy absorption studies, gyroid at 90% infill had the highest peak force (7.35 kN), while honeycomb at 90% infill had the highest mean crushing force (5.679 kN). When improved vibration damping, lightweight design, and mechanical dependability are essential, these optimized structures are ideal for applications such as biomedical orthotic supports, aerospace drone frames, and automotive interior panels.</p>

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Correlation of infill geometry and density with the vibration and mechanical performance of 3D printed carbon fiber-reinforced PA composites

  • 期刊论文

  • 发表日期：

    2025年10月13日

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  • Rashia Begum Syed Ibrahim,
  • Spurgeon Robinson,
  • Saravana Kumar Murugesan,
  • Vasumathi Manivachakan

摘要

Fused filament fabrication (FFF) using carbon fiber-reinforced polyamide (PA/CF) composites offers promising potential for lightweight structural components due to its ease of processing and environmental compatibility. However, there is still a lack of a thorough understanding of how various infill densities and patterns impact PA/CF composites’ mechanical and vibrational behavior. By examining the effects of cubic, gyroid, and honeycomb infill patterns at three infill densities (50%, 70%, and 90%) on mechanical strength, energy absorption, damping, and natural frequency, this study fills this knowledge gap. FFF was used to fabricate PA/CF specimens, which were then tested for tensile, flexural, impact, Shore D hardness, compression, and free vibration properties in accordance with ASTM guidelines. According to the results, Honeycomb continuously demonstrated the highest tensile modulus (~ 1.026 GPa) and impact strength (5.76 kJ/m2), while the gyroid pattern at 90% infill achieved the highest tensile strength (38.41 MPa). With a strength of 63.3 MPa under flexural loading, cubic at 70% infill also demonstrated the highest damping ratio (0.103) and natural frequency (38.54 Hz) in vibration analysis. To determine the optimal infill configuration, the COmplex PRoportional Assessment (COPRAS) multi-criteria decision-making method was employed. According to energy absorption studies, gyroid at 90% infill had the highest peak force (7.35 kN), while honeycomb at 90% infill had the highest mean crushing force (5.679 kN). When improved vibration damping, lightweight design, and mechanical dependability are essential, these optimized structures are ideal for applications such as biomedical orthotic supports, aerospace drone frames, and automotive interior panels.