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<p>This study presents the structural design, precision manufacturing, and compressive behavior of modularly assembled hybrid fiber composite lattice structures fabricated by continuous-fiber 3D printing. Three Kevlar/basalt hybrid fiber lattice configurations, including an unreinforced structure (N-1), a horizontally reinforced structure (Z-1), and a diagonally reinforced structure (Z-2), were designed and manufactured using an in-situ impregnation 3D-printing process combined with a modular assembly strategy. To ensure assembly quality, the effects of line width and corner geometry on manufacturing accuracy were systematically investigated. The mean dimensional deviation decreased from 0.85&#xa0;mm at a line width of 1.0&#xa0;mm to 0.16&#xa0;mm and 0.09&#xa0;mm at line widths of 1.6&#xa0;mm and 2.0&#xa0;mm, respectively. Compression tests revealed that the mechanical performance was jointly affected by reinforcement configuration and printing line width. At a line width of 1.0&#xa0;mm, the Z-2 lattice exhibited the highest energy absorption, achieving a 129% increase compared with the baseline N-1 structure. At a line width of 1.6&#xa0;mm, the Z-1 lattice demonstrated the best overall mechanical performance, with a 50% improvement in energy absorption relative to N-1. Failure analysis showed that no assembly-node detachment occurred during compression, and the load-bearing capacity was primarily governed by structural bending and node compression. Finite element analysis further confirmed that different reinforcement configurations altered the stress-transfer paths and load-bearing regions of the lattice structures. The results provide guidance for the structural design and precision manufacturing of modularly assembled energy absorbing composite lattice structures.</p>

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Structural Design, Fabrication and Mechanical Behaviors of Kevlar/Basalt Hybrid Fiber Composite Lattice Structures

  • 期刊论文

  • 发表日期：

    2026年8月1日

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  • Yongze Li,
  • Shuheng Xiao,
  • Qinglei Sun,
  • Hongyong Jiang

摘要

This study presents the structural design, precision manufacturing, and compressive behavior of modularly assembled hybrid fiber composite lattice structures fabricated by continuous-fiber 3D printing. Three Kevlar/basalt hybrid fiber lattice configurations, including an unreinforced structure (N-1), a horizontally reinforced structure (Z-1), and a diagonally reinforced structure (Z-2), were designed and manufactured using an in-situ impregnation 3D-printing process combined with a modular assembly strategy. To ensure assembly quality, the effects of line width and corner geometry on manufacturing accuracy were systematically investigated. The mean dimensional deviation decreased from 0.85 mm at a line width of 1.0 mm to 0.16 mm and 0.09 mm at line widths of 1.6 mm and 2.0 mm, respectively. Compression tests revealed that the mechanical performance was jointly affected by reinforcement configuration and printing line width. At a line width of 1.0 mm, the Z-2 lattice exhibited the highest energy absorption, achieving a 129% increase compared with the baseline N-1 structure. At a line width of 1.6 mm, the Z-1 lattice demonstrated the best overall mechanical performance, with a 50% improvement in energy absorption relative to N-1. Failure analysis showed that no assembly-node detachment occurred during compression, and the load-bearing capacity was primarily governed by structural bending and node compression. Finite element analysis further confirmed that different reinforcement configurations altered the stress-transfer paths and load-bearing regions of the lattice structures. The results provide guidance for the structural design and precision manufacturing of modularly assembled energy absorbing composite lattice structures.