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<p>Material Extrusion (MEX) is a widely accessible Additive Manufacturing (AM) technique, but is limited by poor mechanical strength, anisotropy, and lack of waterproofing. This study presents a hybrid method combining MEX-printed thermoplastic lattice structures with epoxy resin infusion to enhance structural performance. Epoxy reinforces internal geometry and seals voids, improving tensile and compressive strength and reducing anisotropy. Three materials, Acrylonitrile Butadiene Styrene (ABS), Carbon Fiber (CF) ABS, and Fiberglass (FG) ABS, were tested with various infill patterns, including gyroid, Body Centered Cubic (BCC), and Simple Cubic (SC). Specimens were fabricated, vacuum-infused using a magnetically actuated system, and tested per American Society for Testing and Materials (ASTM) standards. Results showed that epoxy-infused lattices outperformed solid plastic in both strength and isotropy, with CF ABS and shell-based designs yielding the best performance. Fracture analysis confirmed the importance of epoxy continuity in crack resistance. This scalable approach offers a low-cost path to waterproof, high-performance components, particularly for marine applications. Future work includes using advanced thermoplastics, Carbon Nanotube (CNT) reinforced epoxy, and validating performance via an underwater drone case study.</p>

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Mechanical characterization of epoxy-infused lattice structures fabricated via material extrusion for hybrid manufacturing

  • 期刊论文

  • 发表日期：

    2026年2月16日

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  • Mushfig Mahmudov,
  • Ismail Fidan

摘要

Material Extrusion (MEX) is a widely accessible Additive Manufacturing (AM) technique, but is limited by poor mechanical strength, anisotropy, and lack of waterproofing. This study presents a hybrid method combining MEX-printed thermoplastic lattice structures with epoxy resin infusion to enhance structural performance. Epoxy reinforces internal geometry and seals voids, improving tensile and compressive strength and reducing anisotropy. Three materials, Acrylonitrile Butadiene Styrene (ABS), Carbon Fiber (CF) ABS, and Fiberglass (FG) ABS, were tested with various infill patterns, including gyroid, Body Centered Cubic (BCC), and Simple Cubic (SC). Specimens were fabricated, vacuum-infused using a magnetically actuated system, and tested per American Society for Testing and Materials (ASTM) standards. Results showed that epoxy-infused lattices outperformed solid plastic in both strength and isotropy, with CF ABS and shell-based designs yielding the best performance. Fracture analysis confirmed the importance of epoxy continuity in crack resistance. This scalable approach offers a low-cost path to waterproof, high-performance components, particularly for marine applications. Future work includes using advanced thermoplastics, Carbon Nanotube (CNT) reinforced epoxy, and validating performance via an underwater drone case study.