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<p>This research was driven by the increasing demand for lightweight, high-performance energy-absorbing structures in the automotive industry. Achieving optimal specific energy absorption while minimizing Peak Crushing Force (PCF) is crucial to reducing structural damage and impact-related injuries. However, conventional materials and manufacturing methods often fall short in meeting these requirements. Therefore, this study investigates the mechanical and crashworthiness properties of various infill patterns in PLA/Glass Fiber (PLA/GF) composites fabricated using Fused Deposition Modeling (FDM), with the primary goal of identifying the most effective nozzle temperature and infill pattern combination to enhance crashworthiness in 3D-printed parts. Tensile specimens were printed at various nozzle temperatures (210&#xa0;°C, 215&#xa0;°C, 220&#xa0;°C, 225&#xa0;°C, and 230&#xa0;°C) to identify the optimal printing temperature. The optimal printing temperature was then used to fabricate compression specimens with 10 different infill patterns, evaluating key performance parameters such as Peak Crushing Force (PCF), Specific Energy Absorption (SEA), and Crushing Force Efficiency (CFE). The most effective infill pattern was determined and statistically validated using the Complex Proportional Assessment (COPRAS) decision-making approach. The findings of this research indicated that 230&#xa0;°C was the optimal nozzle temperature for PLA/GF composites, resulting in a tensile strength of 28.17&#xa0;MPa and improved layer adhesion, as confirmed by FE-SEM analysis. Among the tested infill patterns, the Cubic Subdivision design demonstrated the highest energy absorption efficiency, surpassing other 3D patterns like Octet and Cubic, owing to its progressive folding failure mode and superior Crash Force Efficiency (CFE). Meanwhile, 2D patterns such as Triangle and Trihexagon exhibited high Specific Energy Absorption (SEA) values of 17.51&#xa0;J/g and 16.16&#xa0;J/g, respectively. However, their higher Peak Crushing Force (PCF) readings of 3.19 kN and 2.66 kN made them less suitable for applications requiring a balance between crashworthiness and structural integrity.</p>

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Effect of nozzle temperature and infill patterns on enhancing crashworthiness performance of 3D printed glass fibre reinforced PLA parts

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2025年10月1日

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  • R. Spurgeon,
  • S. Rashia Begum,
  • M. Saravana Kumar,
  • M. Vasumathi,
  • Adeolu A. Adediran

摘要

This research was driven by the increasing demand for lightweight, high-performance energy-absorbing structures in the automotive industry. Achieving optimal specific energy absorption while minimizing Peak Crushing Force (PCF) is crucial to reducing structural damage and impact-related injuries. However, conventional materials and manufacturing methods often fall short in meeting these requirements. Therefore, this study investigates the mechanical and crashworthiness properties of various infill patterns in PLA/Glass Fiber (PLA/GF) composites fabricated using Fused Deposition Modeling (FDM), with the primary goal of identifying the most effective nozzle temperature and infill pattern combination to enhance crashworthiness in 3D-printed parts. Tensile specimens were printed at various nozzle temperatures (210 °C, 215 °C, 220 °C, 225 °C, and 230 °C) to identify the optimal printing temperature. The optimal printing temperature was then used to fabricate compression specimens with 10 different infill patterns, evaluating key performance parameters such as Peak Crushing Force (PCF), Specific Energy Absorption (SEA), and Crushing Force Efficiency (CFE). The most effective infill pattern was determined and statistically validated using the Complex Proportional Assessment (COPRAS) decision-making approach. The findings of this research indicated that 230 °C was the optimal nozzle temperature for PLA/GF composites, resulting in a tensile strength of 28.17 MPa and improved layer adhesion, as confirmed by FE-SEM analysis. Among the tested infill patterns, the Cubic Subdivision design demonstrated the highest energy absorption efficiency, surpassing other 3D patterns like Octet and Cubic, owing to its progressive folding failure mode and superior Crash Force Efficiency (CFE). Meanwhile, 2D patterns such as Triangle and Trihexagon exhibited high Specific Energy Absorption (SEA) values of 17.51 J/g and 16.16 J/g, respectively. However, their higher Peak Crushing Force (PCF) readings of 3.19 kN and 2.66 kN made them less suitable for applications requiring a balance between crashworthiness and structural integrity.