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<p>Developing lightweight material structure has produced the growth in sustainable and demanding application in the field of aerospace, automotive, and construction. This study is intended to evaluate stress concentration factor (SCF) and mechanical properties around the hole aperture in fabricated structure alternatively layered with ceramic-reinforced polylactic: lightweight Material 1 (LwM1) and carbon-reinforced polylactic acid: lightweight Material 2 (LwM2), resulting in the development of lightweight material structure. Mechanical behavior of fabricated lightweight material structure was evaluated through open-hole tensile testing (OHTT) method along with base LwM1 and LwM2. To obtain a clearer quantification of central aperture, influenced by internal stress state, SCF was evaluated in this study. The experimental results exposed that LwM1 displayed high tensile strength (45.75&#xa0;MPa) and the lowest stress concentration while LwM2 possessed the least tensile strength (36.63&#xa0;MPa) with peak SCF values. Lightweight material structure exhibited tensile strength of 41.25&#xa0;MPa, and an SCF intermediate between LwM1 and LwM2. Further, to correlate the experimental findings, finite element (FE) simulation was used. The combined analysis reveals that lightweight material structure leverages high tensile efficiency of LwM1 and stiffness of carbon reinforcement, contribution a lightweight and mechanically strong alternative to traditional metallic components in advanced structural application.</p>

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Fabrication of Lightweight Material Structure through Additive Manufacturing: Experimental and Finite Element Simulation Validation

  • 期刊论文

  • 发表日期：

    2026年6月18日

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  • Dhinakaran Veeman,
  • Gunal Palani,
  • Mohith Mohan Das,
  • Mohan Kumar Subramaniyan

摘要

Developing lightweight material structure has produced the growth in sustainable and demanding application in the field of aerospace, automotive, and construction. This study is intended to evaluate stress concentration factor (SCF) and mechanical properties around the hole aperture in fabricated structure alternatively layered with ceramic-reinforced polylactic: lightweight Material 1 (LwM1) and carbon-reinforced polylactic acid: lightweight Material 2 (LwM2), resulting in the development of lightweight material structure. Mechanical behavior of fabricated lightweight material structure was evaluated through open-hole tensile testing (OHTT) method along with base LwM1 and LwM2. To obtain a clearer quantification of central aperture, influenced by internal stress state, SCF was evaluated in this study. The experimental results exposed that LwM1 displayed high tensile strength (45.75 MPa) and the lowest stress concentration while LwM2 possessed the least tensile strength (36.63 MPa) with peak SCF values. Lightweight material structure exhibited tensile strength of 41.25 MPa, and an SCF intermediate between LwM1 and LwM2. Further, to correlate the experimental findings, finite element (FE) simulation was used. The combined analysis reveals that lightweight material structure leverages high tensile efficiency of LwM1 and stiffness of carbon reinforcement, contribution a lightweight and mechanically strong alternative to traditional metallic components in advanced structural application.