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<p>This study investigates the interfacial strength and joining behavior of 3D-printed polylactic acid carbon fiber composite (PLA-CFRP) re-entrant core sandwich structures (SWSs) fabricated using two different manufacturing strategies. In Configuration I, the re-entrant core and both facesheets are printed separately and bonded using an adhesive. In Configuration II, the re-entrant core is printed along with one facesheet. The other facesheet is joined with an adhesive. Lap shear tests were carried out to evaluate the bonding integrity and failure characteristics of both configurations. To validate the experimental findings, Cohesive Zone Modeling (CZM) is employed to simulate interface behavior. It effectively captures the initiation and propagation of debonding under shear loading. The model provides insight into stress distribution, load transfer mechanisms, and fracture energy at the adhesive interface. The comparative analysis between the two fabrication approaches highlights the influence of printing on joint strength, stress localization, and failure mode. The findings enhance understanding of adhesive interface behavior in 3D-printed sandwich sheets and provide useful guidelines for optimizing SWSs for lightweight, high-performance applications.</p>

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Experimental and Numerical Investigation of Joining Strength in 3D-Printed PLA-CFRP Re-entrant Core Sandwich Sheets with Two Different Printing Strategies

  • 期刊论文

  • 发表日期：

    2026年5月17日

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  • Phul Babu,
  • R. Ganesh Narayanan,
  • Nelson Muthu

摘要

This study investigates the interfacial strength and joining behavior of 3D-printed polylactic acid carbon fiber composite (PLA-CFRP) re-entrant core sandwich structures (SWSs) fabricated using two different manufacturing strategies. In Configuration I, the re-entrant core and both facesheets are printed separately and bonded using an adhesive. In Configuration II, the re-entrant core is printed along with one facesheet. The other facesheet is joined with an adhesive. Lap shear tests were carried out to evaluate the bonding integrity and failure characteristics of both configurations. To validate the experimental findings, Cohesive Zone Modeling (CZM) is employed to simulate interface behavior. It effectively captures the initiation and propagation of debonding under shear loading. The model provides insight into stress distribution, load transfer mechanisms, and fracture energy at the adhesive interface. The comparative analysis between the two fabrication approaches highlights the influence of printing on joint strength, stress localization, and failure mode. The findings enhance understanding of adhesive interface behavior in 3D-printed sandwich sheets and provide useful guidelines for optimizing SWSs for lightweight, high-performance applications.