Session: 03-15-03: Smart Manufacturing and Robotics for the Future III

Paper Number: 165933

Investigating Mechanical Behaviour of Celtic Design-Inspired Lattice Structures 

The continuous advancements in additive manufacturing have facilitated the production of complex geometries with high precision and accuracy, making it a valuable tool for addressing engineering challenges across multiple industries. One such geometry, lattice structures, consists of repeated unit cell patterns that can be tailored in terms of geometry and density to achieve specific mechanical properties. These structures have found significant applications in aerospace, automotive, and biomedical engineering due to their high strength-to-weight ratio, tunable mechanical characteristics, and energy absorption capabilities. The ability to customize lattice structures by modifying material composition further enhances their functional adaptability for specific use cases. However, limited research has been conducted on the effects of multi-material integration within lattice structures and its impact on their mechanical performance. This study aims to investigate the properties of novel multi-material lattice structures through a combination of compression testing, vibrational analysis, finite element modeling (FEM), and mathematical methods. The primary objective is to evaluate the extent to which multi-material integration influences mechanical performance, particularly in terms of strength, flexibility, and vibration dampening.

Lattice structures were designed using SolidWorks and manufactured through fused deposition modeling (FDM) utilizing a Prusa XL 3D printer equipped with five toolheads. The base material for the structures was polyethylene terephthalate glycol (PETG), chosen for its high strength and durability, while thermoplastic polyurethane (TPU) was selectively incorporated at the corners and joints to enhance flexibility and vibration absorption. Experimental testing involved compression tests to evaluate load-bearing capacity and structural integrity, along with vibrational analysis to assess dynamic response characteristics. Additionally, finite element simulations were conducted using ANSYS, and the results were further validated through mathematical modeling to ensure accuracy and consistency. The integration of experimental testing, numerical simulation, and analytical modeling provided a comprehensive understanding of the mechanical behavior of the multi-material lattice structures.

The findings of this research demonstrate that incorporating TPU within a PETG lattice structure results in a unique combination of mechanical properties. While PETG provides the necessary structural integrity, the inclusion of TPU significantly enhances flexibility and vibration dampening without compromising overall strength. The results from FEM simulations and mathematical models closely correlated with the physical testing outcomes, exhibiting minimal deviation. These findings underscore the potential of multi-material lattice structures in engineering applications requiring customized mechanical behavior, such as impact-resistant components, vibration-isolating structures, and lightweight, high-performance materials. This study contributes to the growing body of research on advanced lattice structures by providing insights into how multi-material additive manufacturing can be leveraged to optimize mechanical properties. The results highlight the importance of material selection and geometric design in achieving desired structural performance, paving the way for future innovations in lattice-based engineering applications.

Presenting Author: Rupal Srivastava South East Technological University Waterford

Presenting Author Biography: Dr. Rupal Srivastava is a Lecturer at the Faculty of Engineering and Built Environment, South East Technological University Waterford, Ireland. Prior to this she was a Marie Curie Postdoctoral Researcher at the Science Foundation Ireland- Conform Center, and completed her PhD from the Indian Institute of Technology Kanpur, India.

Her interests lie in the fields of Smart Materials, Wearables, AR/VR and Cobotic Applications in the Manufacturing, Healthcare, Education, and Interactive Arts sectors.

Authors:

Josh Lacken South East Technological University Waterford
Keith Tracey South East Technological University Waterford
Amanpreet Singh Durham University
Rupal Srivastava South East Technological University Waterford