Effect of Internal Cellular Geometry on the Impact Performance of 3D-Printed Structures

Document Type : Original Article

Authors

1 Department of Mechanical Engineering, Arak University of Technology, Arak, Iran.

2 Department of Mechanical Engineering, Faculty of Engineering, Ayatollah Boroujerdi University, Boroujerd, Iran.

3 Department of Mechanical Engineering, Arak University of Technology, Arak, Iran

4 Department of Mechanical Engineering, Shahrekord University, Shahrekord, Iran

10.61186/masm.4.4.623.
Abstract
The simultaneous enhancement of impact resistance and reduction of structural weight presents a key challenge in engineering applications, particularly in aerospace and automotive industries. This study aims to develop lightweight high-performance structures by optimizing the internal cellular geometry of 3D-printed components. Polylactic acid (PLA) specimens were fabricated using fused filament fabrication with three cellular patterns (circular, decagonal, and hexagonal), and two orientation schemes (linear and diagonal). The impact behavior of each configuration was evaluated through both experimental Charpy impact tests and finite element simulations. A systematic analysis was performed to assess the influence of cell geometry and orientation on energy absorption, weight reduction, and fracture characteristics. The results revealed that hexagonal cell configurations yielded the highest energy absorption, with up to a 62% increase in impact strength despite a 36% reduction in mass compared to baseline designs. Diagonally oriented cells significantly prolonged fracture duration, showing a 575% increase in time to failure, attributed to the formation of additional plastic hinges and inclined crack paths. These findings demonstrate that strategic internal cell design can substantially improve mechanical performance without additional material usage.

Keywords


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Volume 4, Issue 4
Winter 2025
Pages 623-644

  • Receive Date 22 April 2025
  • Revise Date 12 May 2025
  • Accept Date 29 May 2025