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Abstract
A new class of lightweight and 3D printable architected sandwich structures, named as meta-
sandwich structures, has been introduced. These lightweight sandwich structures, which have
been made of mechanical metamaterials as the core, show many advantages such as high
stiffness-to-weight ratio and high energy absorption capability. In this paper, finite element
simulation and experimental testing were implemented to evaluate the structural durability of 3D
printed meta-sandwiches under quasi-static flexure and low-velocity impact tests. We
specifically investigated the failure mechanism, energy absorption and multi-hit capability of 3D
printed polymeric meta-sandwich structures made of cubic, octet and Isomax cellular cores.
Three-point bending experiments on 3D printed meta-sandwich beams were conducted to
evaluate their flexural stiffness and quasi-static energy absorption, followed by low-velocity
impact tests to determine their dynamic energy absorption and multi-hit capabilities. Analytical
formulations were also developed to capture the failure mechanism in the architected sandwich
structures. It is found that the core topology and geometrical parameters have significant effects
on failure mechanism and energy absorption of meta-sandwich structures. For example, Isomax
meta-sandwich structures have high quasi-static and dynamic impact energy absorption
capabilities.
*
Address correspondence to: hamid.akbarzadeh@mcgill.ca, Tel: +1 (514) 398-7680.
https://www.mcgill.ca/bioeng/faculty-and-staff/abdolhamid-akbarzadeh-shafaroudi.
1
1. Introduction
Lightweight sandwich structures are nowadays extensively used in aerospace, marine,
automobile, windmill and building industrial sectors, mainly due to their excellent
multifunctional properties such as high flexural stiffness, thermal insulation and high energy-
absorption capabilities [1, 2]. Sandwich structures consist of three components: two thin solid
face-sheets with high flexural stiffness at top and bottom surfaces separated by a relatively thick
lightweight core. The lightweight core connects the face-sheets with a little increase in weight,
providing a high bending and buckling resistance [3] and excellent shear stiffness and energy
absorption capability [4]. The optimized lightweight sandwich structures are made of architected
cellular cores, which carry transverse shear and compression loads, and solid face-sheets which
carry in-plane load and flexure [1]. Concerning limited energy and material resources,
lightweight micro-architected sandwich structures are of growing interest since they can
simultaneously reduce the weight of structural elements while satisfying multiple functionalities,
e.g. structural rigidity [5], heat exchanging [6] and electrical properties [7]. Recent advances in
manufacturing, e.g. additive manufacturing (or 3D printing) and laser cutting, have enabled
manufacturing of architected cellular cores of free-form two-dimensional (2D) and three-
dimensional (3D) topologies, which are impossible to be fabricated by conventional
manufacturing processes of sandwich structures, e.g. extrusion, expansion and corrugation [8].
Opposed to foaming process (e.g. compression molding, slabstock, casting and solid-gas eutectic
solidification [3]), which leads to manufacturing of porous materials with random morphologies,
3D printing offers a robust manufacturing process for controlling the microarchitecture of
cellular materials made of polymers, composites and metals which makes 3D printed materials
applicable in medicine as a scaffold for regeneration of tissues and organs [9], in the
electromagnetic industry as interference shielding [10-12], in space sectors for satellite structures
[13] or in thermal management as heat exchangers [14]. Among advantages of 3D printing, the
programmability of multifunctional properties over a multiple length scale through controlling
architecture and geometrical features of cellular cores [15-18] can be highlighted, however
reliability of 3D printed components is yet to be examined as 3D printing commonly leads to
manufacturing defects [19, 20].
The structural and energy absorption performance as well as failure mechanism of a cellular
sandwich structure depend on its constituent material, geometrical parameters and core cell
2
topology. Among all possible topologies, conventional honeycombs have been widely studied
[21-23]. Sandwich structures with conventional honeycomb cores are stiff and lightweight and
are capable of absorbing high energy under impact loads and shockwaves, for example for
applications in sports goods (e.g. helmet) and vehicles (e.g. bumpers) [24, 25]. However, they
commonly suffer from the closed-cell architecture of their core due to gas retention and moisture
trapping within their core [1]. Moisture trapped in the closed-cell cores increases the weight of
sandwich structures and shifts their center of gravity, a culprit which can be diminished by open-
cell cores [1] such as truss-like lattices [26, 27]. Compared to regular honeycombs, it has been
shown that lattice cores can significantly increase the buckling resistance and energy absorption
capability of sandwich structures [28, 29]. Another type of cellular cores is auxetic cells which
have been examined in recent papers [30, 31] due to their unusual deformation mechanism, i.e.,
negative Poisson’s ratio. The structural responses of sandwich structures with auxetic cores were
analyzed under small deformation [32, 33], large deformation [34, 35], bending [36, 37] and
low-velocity impact [38]. It has been shown that the angle of auxetic cores has a significant
influence on the structural responses of the sandwich structures [36]. In addition, it was found
that the auxetic composite panels were able to absorb the dynamic impact energy through plastic
deformation and the displacements of the back face-sheet can consequently be reduced [38].
Recent studies have shown that architected 3D printed cores, especially those with 3D
microarchitecture, present a new class of highly-optimized energy-absorption structures that
offer flexibility in controlling the response of sandwich structures under quasi-static and impact
loads [39-43]. Lightweight Isomax cores, as one of the new architected cellular structure, are
maximally stiff in all directions with maximum theoretical toughness [44]. Although a few
studies have been performed on sandwich structures with 3D printed architected cores to
evaluate flexural behavior [44-46] and out-of-plane compressive strength [47, 48], less attention
has been paid to explore the failure mechanism, energy absorption and multi-hit capabilities of
additively manufactured sandwich structures with 3D architected core topologies subjected to
quasi-static and impact loads.
Present research investigated the structural responses, failure mechanism, multi-hit and energy
absorption capabilities of 3D printed architected sandwich structures with mechanical
metamaterial cores, e.g. cubic, octet and Isomax cell topologies. Their behavior was studied to
efficiently optimize the energy absorption performance. The failure mechanism and energy
3
absorption capability of a meta-sandwich structure are influenced by its: (a) Total dimensions
(length, width and thickness), (b) Mass (relative density), (c) Properties of the base material used
to build the core and face-sheets and (d) Core topology. The current study focuses on the effect
of architected core topologies and relative density on the structural responses (Section S4 of
Supplementary Document), flexural stiffness (Section 3.1.3), energy absorption performance
(Sections 3.1.2 and 3.2.2), failure mechanism (Section 3.1.4) and multi-hit capability (Section S2
of Supplementary Document) of meta-sandwich structures 3D printed by fused deposition
modelling (FDM). The current research sheds lights on the durability of 3D printed meta-
sandwich structures as lightweight load-bearing and energy absorbent engineering components.
z
z
b
a a b
x y y
t x
tf tc tf t
tc
Ls Face-sheets
(a) (b)
Figure 1: Geometry and coordinate system: (a) Meta-sandwich beam and (b) Meta-sandwich plate.
Figure 1 shows the dimensions of the meta-sandwich beams and plates including length (a),
width (b), total thickness (t), core thickness (tc) and face-sheet thickness (tf). The coordinate
system (x, 𝑦, z) is located at the mid-plane of the meta-sandwich structures. The dimensions of
4
sandwich beams and plates, presented in Table 1, have been designed based on ASTM D3763
[49], ASTM C393 [50] and experimental testing limitations such as capacity or geometrical
restrictions of flexural tester.
(b)
Figure 2: (a) Unit cells of the mechanical metamaterial cellular cores and (b) Geometrical characteristics of octet
unit cell.
5
Although closed-cell cubic and octet unit cells store a maximum amount of strain energy, they
are highly anisotropic [44]. As a result, Isomax [44] has recently been introduced by combining
cubic and octet unit cells to achieve an isotropic cellular material reaching the upper bound of
Hashin-Shtrikman for elastic stiffness and to show a maximum elastic strain energy storage.
Isomax cells consist of distributed networks of plates to efficiently transfer loads between
neighboring members leading to isotropic structural properties [44].
Table 2: Representative of 3D printed meta-sandwich beams and plates fabricated by FDM 3D printing.
6
Therefore, all samples were 3D printed along the same orientation. Examples of 3D printed
meta-sandwich beams and plates with four core topologies are shown in Tables 2 and S.1 of
Supplementary Document.
Figure 3: (a) Engineering stress-strain curves of 3D printed PLA dogbone coupons under tensile load, (b) 3D
printed dogbone coupons before and after tensile tests.
It is often the case with FDM 3D printing processes that material properties exhibit a certain
degree of anisotropy. Yang et al. [52] showed that the 3D printing orientation of 45° could
provide an approximation for evaluating the material properties of 3D printed materials, e.g.
Young’s modulus and Poisson’s ratio. Here, Dogbone coupons were fabricated in the orientation
of ±45° with respect to the loading axis (See Fig. 3b). Figure 3a presents the experimental tensile
stress-strain curves of 3D printed PLA coupons. The averaged experimental properties of PLA
are reported in Table 3.
7
Table 3: Experimental properties of 3D printed PLA dogbone coupons.
Young’s Ultimate Yield strain Poisson’s ratio Plastic strain
̅)
modulus (𝑬 ̅u)
strength (𝑺 (𝜺̅Y) (υp)* at break (𝜺̅p)
Average mechanical
2.3 ± 0.1 GPa 46.1 ± 1 MPa 0.024 ± 0.001 0.38 ± 0.003 0.085 ± 0.001
properties
*
Measured after failure of the PLA samples.
Impactor
Simply supports
According to ASTM C393 [50], the span of sandwich beams must be sufficiently short to
determine the core shear strength; in this condition, the core shear failure occurs prior to the
face-sheet failure. Therefore, the span length of the beam was set at 90 mm with respect to the
total thickness of one of the meta-sandwich beams selected as 30 mm (Ls = 3).
8
To evaluate dynamic energy absorption capability of meta-sandwich plates (See Table S.3 of
Supplementary Document) The low-velocity impact tests were performed using a drop weight
machine with a 10 kN load cell based on the guidelines given in ASTM standard D3763 [49].
The resolution of the load cell (MTS 661 19E-04 with maximum capacity of 25 kN) was 0.01%
of the maximum load. The impactor had a mass of 22 kg and a diameter of 25.4 mm. During the
impact test, the samples were constrained between two parallel rigid supports with 75 mm
diameter holes at their centers (See Fig. 5). Sufficient clamping pressure was applied to prevent
the samples from slipping during the experiments.
Impactor
Guide rail
Sandwich plate
9
Xf
Pmax
1
Ls
6
4t t t
f f c 4t 2f
4 𝑘 𝐸𝑐
where Xf represents the face-sheet compressive yield. In addition, β = √4𝐷 , where k =
𝑓 𝑡𝑐
𝐸𝑓 𝑡𝑓3
and Df = ; Df is the bending stiffness of the face-sheet about its neutral axis and Ec and
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Ef are Young’s modulus of the core and longitudinal modulus of the face-sheets,
respectively.
(b) The face-sheet wrinkling occurs due to the local buckling related to the waviness of the
face-sheet as well as the difference between the moduli of the face-sheet and core materials
[53]. Since sandwich beams have high-strength cores, high elastic moduli of the face-sheet
and cellular core materials and small amplitude in waviness of the face-sheet, the face-
sheet wrinkling failure mode does not occur.
Pmax 2Sc tc t f 2
where Sc represents the core shear yield strength.
(b) For core compressive yielding, the maximum load per unit width is expressed as [53]:
2Xc
Pmax
3
where Xc represents the core compressive yield strength.
(c) For core buckling, FEA is used to capture this type of failure modes.
10
structures do not require adhesion between face-sheet and cellular core, which dramatically
reduces the possibility of debonding of the core and face-sheets [1].
It should be mentioned that the impact failure mechanisms have been discussed in Section S3 of
Supplementary Document.
11
sandwich structures. It should be noted that the gravitational force was negligible compared to
the force applied on the impactor.
Face sheet
Fixed support
3D-printed core
(a) (b)
Figure 6: Finite element models for (a) 3-point bending and (b) Impact tests.
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assumed to be elastic-perfectly plastic which can cause the difference between experimental and
FEA results especially for deformation ranged beyond the elastic domain. (b) FDM 3D printing
fabricated meta-sandwich panels by depositing molten layers in z-direction. The final 3D printed
products were layered in a microscopic layer; however, we considered perfectly bonded layers
when we implemented finite element analysis for modeling the FDM 3D printed products which
slightly over predicted their stiffness and strength. In addition, the current FEA considered 3D
printed PLA as isotropic materials; however, since the molten layers were deposited based on the
3D printing toolpath, the 3D printed materials can be orthotropic which has been overlooked in
the current analysis, and (c) The 3D printed PLA polymers could slightly lose their properties
when subjected to air or elevated environmental conditions. Since the tensile test on dogbone
coupons and the flexure and impact tests have been conducted at different time, this can be
another reason for slight difference between numerical results (obtained based on experimental
data found by tensile test on 3D printed dogbane coupons) and experimental data.
Figure 7: (a) Experimental and FEA force-displacement curves of 3D printed architected meta-sandwich beams
including Isomax, octet and cubic cores with the relative densities of 30% and 50%, (b) Experimental deformed
shapes and (c) The corresponding FEA meta-sandwich beams.
13
During the 3-point bending test, the platen struts are subjected to tension, compression, or
bending, a complex stress state which is not well-captured in a simple elastic-perfectly plastic
material model. Anisotropy, porosity and imperfections caused by 3D printing should also be
considered in the numerical simulation to obtain results closer to experimental data on 3D
printed sandwich structures. These results suggest the possibility of tailoring core topology of
lightweight sandwich structures to achieve desirable flexural properties for certain engineering
applications.
Table 5: Comparison between FEA and experimental data of meta-sandwich beams (7×1×1 unit cells).
Maximum load (kN) Flexural stiffness (kN/mm)
Core architecture
FEA Experiment FEA Experiment
Isomax 4.57 4.56 2.21 2.11
ρ = 30% Octet 4.84 4.82 2.29 2.24
Cubic 5.10 5.09 2.11 2.02
Isomax 6.87 6.85 3.02 2.90
ρ = 50% Octet 6.94 6.92 2.91 2.84
Cubic 6.94 6.93 3.00 2.95
14
sheets and horizontal platen and buckling of vertical platen struts. The buckling phenomenon
does not result in a catastrophic failure; instead the buckled cellular core enables the sandwich
structure to absorb energy under larger deformation. Therefore, global failure mode controls the
deformation of auxetic (ρ = 30% and 50%), octet (ρ = 30%) and Isomax (ρ = 30%) sandwich
beams. However, it should be noted that the core deformations in Isomax, octet and cubic
sandwich beams are irreversible after unloading.
Figure 8: Bending characteristic of architected meta-sandwich beams with different core architectures. Beams are
composed of 7×1×1 unit cells (Ls = 3): (a) Load-deflection curves and (b) Deformed configurations of each meta-
sandwich beam right before failure.
15
Figure 9: Bending characteristic of architected sandwich beams with different core architectures. Beams are
composed of 7×2×2 unit cells (Ls = 1.8): (a) Load-deflection curves and (b) Deformed configurations of each meta-
sandwich beam right before failure.
16
four 3D printed sandwich beams, it is found that octet and Isomax sandwich beams exhibit a
better performance over the cubic or auxetic sandwich beams. Isomax sandwich beam has the
same level of response forces but with smaller energy absorption ability compared to the octet
sandwich beam. Moreover, while the global deformation is more dominant in the failure
mechanism of Isomax meta-sandwich beams, octet and cubic meta-sandwich beams are more
prone to failures caused by local deformations.
Figure 10: Bending properties of the 3D printed meta-sandwich beams composed of 7×1×1 unit cells (Ls = 3): (a)
Bending stiffness, (b) Maximum load, (c) Displacement at maximum load and (d) Energy absorption.
Figure 11 shows the experimental results for the bending stiffness, maximum load, displacement
at maximum load and energy absorption of meta-sandwich beams composed of 7×2×2 unit cells
(Ls = 1.8). While the cubic meta-sandwich beam with higher span-to-thickness ratio (Ls = 3)
shows the lowest energy absorption among all meta-sandwich beams, for the lower span-to-
thickness ratio (Ls = 1.8), it shows the highest energy. This can be justified by the buckling of the
17
vertical platen struts in cubic unit cells instead of fracture, leading to absorption of higher energy
during the loading.
Figure 11: Bending properties of the 3D printed meta-sandwich beams composed of 7×2×2 unit cells (Ls = 1.8): (a)
Bending stiffness, (b) Maximum load, (c) Displacement at maximum load and (d) Energy absorption.
Three terms, introduced in the right hand side of Eq. (4), describe the bending stiffness of the
faces and the core about their own centroid, and the bending stiffness of the faces about the
18
centroid of the sandwich beam, respectively. It should be mentioned that Young’s modulus of the
core of sandwich beams is extracted from reference [44]; for other core topologies, the
computational homogenization technique [7], e.g. standard mechanics or asymptotic
homogenization, can be used to obtain the effective properties. Young’s modulus of the face-
sheet is equal to PLA Young’s modulus. The equivalent shear rigidity is defined as [46]:
𝑏(𝑡𝑐 +𝑡𝑓 )2 𝐺𝑐
(𝐴𝐺)𝑒𝑞 = (5)
𝑡𝑐
where the shear modulus of the core Gc is obtained by considering a periodic core under a shear
strain in FEA [44]. When a load P is applied, the deflections δ of the sandwich beam is the
summation of the bending (𝛿𝑏 ) and shear (𝛿𝑠 ) components:
𝑃𝑎3 𝑃𝑎
δ = 𝛿𝑏 + 𝛿𝑠 = 48(𝐸𝐼) + 4(𝐴𝐺) (6)
𝑒𝑞 𝑒𝑞
𝑃
Using Eqs. (4)-(6), the theoretical flexural stiffness of the meta-sandwich beam is =
𝛿
48(𝐸𝐼)𝑒𝑞 (𝐴𝐺)𝑒𝑞
. Table 6 presents the comparison between the flexural stiffness obtained by
𝑎3 (𝐴𝐺)𝑒𝑞 +12𝑎(𝐸𝐼)𝑒𝑞
the theoretical formulation, FEA and experimental testing. The theoretical flexural stiffness is up
to 12% higher than the experimental data.
Table 6: Comparison between the flexural stiffness of meta-sandwich beams obtained by 3-point bending
experiment, theoretical formulation and FEA of rotated cubic cores.
Flexural stiffness (kN/mm)
Experimental Theoretical
FEA
data formulation
Cell density and type
Isomax 2.11 2.35 2.21
Octet 2.24 2.39 2.29
ρ = 0.3
θ = 0° θ = 15° θ = 30° θ = 45°
Cubic 2.02 2.25
7×1×1 2.11 1.89 1.71 1.52
(Ls = 3) Isomax 2.90 3.15 3.02
Octet 2.84 3.04 2.91
ρ = 0.5
θ = 0° θ = 15° θ = 30° θ = 45°
Cubic 2.95 3.18
3.00 2.74 2.59 2.30
Isomax 8.25 8.46 8.33
Octet 5.74 5.92 5.82
ρ = 0.3
θ = 0° θ = 15° θ = 30° θ = 45°
Cubic 5.73 5.95
7×2×2 5.81 5.61 5.48 5.20
(Ls = 1.8) Isomax 9.50 9.69 9.60
Octet 8.73 8.97 8.80
ρ = 0.5
θ = 0° θ = 15° θ = 30° θ = 45°
Cubic 5.83 6.01
5.91 5.69 5.50 5.31
19
As mentioned in Section 2.1.1, as oppose to cubic and octet cells, Isomax cells are mechanically
isotropic. To show this advantage of Isomax over octet and cubic cells, we simulated cubic meta-
sandwich beams out of 15°, 30° and 45° rotated cells (in-plane rotations, See Section S.4 of
Supplementary Document) for both ρ = 30% and 50% under 3-point bending load. Table 6
presents the flexural stiffness of rotated cubic sandwich beams compared to regular cubic beams
(for Ls = 1.8 and 3). By increasing the rotation angle of the cubic core, the flexural stiffness
decreases since less material is involved in the load bearing characteristics of the meta-sandwich
beam.
sandwich beams under 3-point bending loads (See Table 5). Finally, the core compressive yield
strengths (Xc) are obtained by FEA of periodic cubic, octet and Isomax unit cells under a
distributed compressive load. As presented in Table 7, theoretical formulation and FEA detect
the same failure mechanism as occurred in experiments for most of the cases. For cubic (ρ = 30%
and 50%) and octet (ρ = 50%) meta-sandwich beams, the failure starts with core buckling,
detected by FEA, followed by failure in the bottom face-sheet due to a maximum tensile stress.
This failure mode is not covered by the theoretical developments making it incapable of
capturing the phenomenon occurred during the experiments. The failure mechanisms are
illustrated in Fig. 12.
Table 7: Comparison of the failure mechanisms obtained by theoretical formulations, FEA & experimental testing.
Methods
Cell density and type Failure mechanisms Experimental Formulatio
tests ns & FEA
Isomax Core buckling & top face-sheet failure ✔ ✔
7×1×1 ρ = 0.3 Octet Core buckling & top face-sheet failure ✔ ✔
(Ls = 3) Cubic Top face-sheet failure ✔ ✔
ρ = 0.5 Isomax Top face-sheet failure ✔ ✔
20
Octet Top face-sheet failure ✔ ✔
Cubic Top face-sheet failure ✔ ✔
Core buckling following by failure in the
Isomax ✔ ✔
top face-sheet
ρ = 0.3 Octet Core shear ✔ ✔
Core buckling following by failure in the
Cubic ✔ --
bottom face-sheet
7×2×1
Core buckling following by failure in the
(Ls = 1.8) Isomax ✔ ✔
top face-sheet
Core shear following by failure in the
ρ = 0.5 Octet ✔ --
bottom face-sheet
Core buckling following by failure in the
Cubic ✔ --
bottom face-sheet
ρ = 0.3 (Core buckling & top face-sheet ρ = 0.3 (Core buckling & top face-sheet
Ls = 3 ρ = 0.3 (Top face-sheet failure)
failure) failure)
ρ = 0.5 (Top face-sheet failure) ρ = 0.5 (Top face-sheet failure) ρ = 0.5 (Top face-sheet failure)
ρ = 0.5 (Core buckling following by failure ρ = 0.5 (Core shear following by failure ρ = 0.5 (Core shear following by failure
in the top face-sheet) in the bottom face-sheet) in the bottom face-sheet)
21
= 30% is compared with the experimental data in Fig. 13 for the impact energies of 3J and 40J.
Good agreements are found between the results of experimental tests and numerical analyses
with a difference less than 8%. The reasons why the simulated results are slightly higher than the
experimental data were mentioned in Section 3.1.1. In the energy absorption-time history plot,
the amounts of absorbed and returned (released) energies during the impact test can be observed.
The absorbed energy is the energy mostly dissipated by failure mechanisms, e.g. delamination
[55] and cracking [56]. The returned (released) energy is the elastic energy. Herein, we define
𝐴𝑏𝑠𝑜𝑟𝑏𝑒𝑑 𝑒𝑛𝑒𝑟𝑔𝑦
the energy absorption percentage based on the following ratio: % [19].
𝑀𝑎𝑥𝑖𝑚𝑢𝑚 𝑖𝑚𝑝𝑎𝑐𝑡 𝑒𝑛𝑒𝑟𝑔𝑦
The comparison of energy absorption percentage of meta-sandwich plates with the relative
densities of ρ = 30% and 50% subjected to 3J and 40J impacts evaluated by the experiments and
FEA are presented in Section S6 of Supplementary Document.
Figure 13: Experimental and FEA energy time-histories of 3D printed Isomax meta-sandwich plates with the
relative density of ρ = 30% for 3J and 40J impact energies.
22
Figure 14: Energy time-history of experimental impact test on 3D printed meta-sandwich plates of
alternative core topology and relative density for 3J and 40J impacts.
The experimental results of the energy absorption and maximum load of meta-sandwich plates (ρ
= 30% and 50%) subjected to a 3J impact load are presented in Fig. 15. At low impact energy
tests, Isomax, octet and cubic meta-sandwich plates show the same energy absorption
performance which is higher than that of the auxetic sandwich plate. On the other hand, the
magnitude of maximum contact load for Isomax, octet and cubic meta-sandwich plates are not
the same. While the cubic meta-sandwich plate shows the maximum contact load, auxetic
sandwich plates exhibit the minimum magnitude of the contact load for both 30% and 50%
relative densities. The impact energy applied to the sandwich plates is primarily absorbed
through failure and damage of core and face-sheets. As shown in Fig. 15, the maximum contact
load increases significantly by increasing the relative density. However, energy absorption
capability of Isomax and auxetic sandwich plates either stays almost the same or marginally
drops. This observation corresponds to the increased stiffness caused by increasing the relative
density. The deformation configuration and equivalent stress distribution on the cross section of
the meta-sandwich plates under a 3J impact are shown in Fig. 15.
23
Figure 15: Impact properties of 3D printed meta-sandwich plates with Isomax, octet, cubic and auxetic cellular
cores under a 3J low-velocity impact: (a) Energy absorption and (b) Maximum load.
Figure 16 shows the experimental results of the energy absorption capability and maximum load
of meta-sandwich plates (ρ = 30% and 50%) subjected to a 40J impact load. For the higher
impact energy, Isomax meta-sandwich plate shows the highest energy absorption capability for
the sandwich plates with the relative density of ρ = 30%. However, for the higher relative
densities, octet meta-sandwich plate illustrates the highest energy absorption capability. The
reason is both Isomax and octet meta-sandwich plates are controlled by a local failure mode. The
buckling of vertical platen struts occurs more in Isomax core compared to octet ones. The
buckling makes the sandwich plate deform further and absorb more energy. By increasing the
relative density, octet meta-sandwich plates show higher energy absorption capability than
Isomax meta-sandwich plate. This is due to the fact that Isomax core is stiffer than the octet core,
leading to less global deformation. In addition, by increasing the relative density, vertical walls
inside the Isomax become more and more supported by the inclined walls and therefore less
buckling is possible inside the cells of the core.
24
Figure 16: Impact properties of the 3D printed meta-sandwich plates including Isomax, octet, cubic and auxetic
cores under a 40J impact energy: (a) Energy absorption and (b) Maximum load.
The octet meta-sandwich plate with ρ = 30% has a lower maximum contact force under the
impact load, which can have applications in minimizing the impact force applied to the structures
protected with 3D printed shock absorber. It is worth mentioning that auxetic sandwich plates
have lower energy absorption capability than the other sandwich plates. In addition, the energy
absorption capability of Isomax meta-sandwich plate decreases by increasing the relative density,
since local failure is a more dominate failure mode for higher relative densities than the global
failure which occurs in lower densities.
4. Conclusions
A numerical methodology, validated by experimental testing, was developed in this study to
optimize the quasi-static and dynamic energy absorption performance of a new generation of 3D
printed lightweight sandwich structures made of metamaterial cores. Four different core
topologies were 3D printed out of PLA and tested under quasi-static 3-point bending and
25
dynamic low-velocity impact conditions. The structural responses, failure mechanisms, flexural
stiffness, multi-hit and energy absorption capabilities of these meta-sandwich structures were
compared with their counterparts made of an auxetic cellular core. It is found that the core
topology and geometrical parameters of the meta-sandwich structures play significant roles on
their failure mechanism and energy absorption capability. As an example, for Ls = 3, octet meta-
sandwich beams with ρ = 30% showed a higher quasi-static energy absorption capability than the
other cell topologies, while the contact load during the 3-point bending test was also higher than
the meta-sandwich beams made of the other cell topologies. However, for Ls = 1.8, Isomax and
cubic meta-sandwich beams with ρ = 50% showed a higher static energy absorption capability
than the other meta-sandwich beams. However, for dynamic energy absorption, Isomax, octet
and cubic meta-sandwich plates had almost the same ability, all higher than the auxetic core for
low impact energy. For higher impact energy, octet meta-sandwich plates show higher energy
absorption performance. Regarding the multi-hit capability, 3D printing direction plays an
important role on multi-hit resistance of meta-sandwich plates. Finally, the designed meta-
sandwich structures could lead to significant weight reduction along with optimized energy
absorption capability without compromising their other mechanical performance.
Acknowledgments
H. Yazdani Sarvestani is supported by McGill University and an FRQNT (Fonds de recherche
Nature et technologies) postdoctoral fellowship award. A.H. Akbarzadeh acknowledges the
financial support provided by McGill University and Natural Science and Engineering Research
Council of Canada (NSERC) through NSERC Discovery Grant RGPIN-2016-04716. Authors
also acknowledge the collaborations of Mathieu Lapointe, Jeremi Bussieres and Thomas Guinot
from Composites Development Center of Quebec (CDCQ) for conducting 3-point bending tests
as well as the discussion with Prof. R. Boukhili and Ms. R. Ouadday at École Polytechnique de
Montréal for the low-velocity impact tests.
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29
3D Printed Meta-Sandwich Structures:
Failure Mechanism, Energy Absorption and Multi-hit Capability
H. Yazdani Sarvestani1, A.H. Akbarzadeh1, 2†, A. Mirbolghasemi1, K. Hermenean3
1
AM3L Laboratory, Department of Bioresource Engineering, McGill University, Island of Montreal, QC H9X
3V9 Canada
2
Department of Mechanical Engineering, McGill University, Montreal, QC H3A 0C3 Canada
3
MACHINA Corp., Edmonton, AB T6H 2H3 Canada
Table S.1: Representative of 3D printed meta-sandwich beams and plates fabricated by FDM 3D printing.
No. of
(7×2×2) (7×1×1)
cells
Isomax beam
Octet beam
Cubic beam
Auxetic beam
†
Address correspondence to: hamid.akbarzadeh@mcgill.ca, Tel: +1 (514) 398-7680.
https://www.mcgill.ca/bioeng/faculty-and-staff/abdolhamid-akbarzadeh-shafaroudi.
30
Meta-sandwich plate
Table S.2: Architected meta-sandwich beams with four periodic core topologies.
Cubic Octet Isomax Auxetic
Table S.3: Architected meta-sandwich plates with three periodic core topologies.
Cubic Octet Isomax
31
S2. Effects of Core Topology of Meta-sandwich Plates on Multi-hit Capability
The effects of core topology of 3D printed meta-sandwich plates on their multi-hit and energy
absorption capabilities were investigated. The same drop weight machine was used and the
accuracy of the load cell (MTS 661 22D-01 with maximum capacity of 250 kN) was 0.01% of
the maximum load. The 3D printed octet and Isomax meta-sandwich plates with two relative
densities of 30% and 50% are subjected to multi-hit low-velocity impact loads of 60J and 120J.
The numerical analysis has also been conducted to study the multi-hit capability. As shown in
Fig. S.1, there is a good agreement between the FEA results and measured experimental data. It
is worth mentioning that failure of the sandwich plates is considered in FEA based on the
maximum equivalent plastic strain of PLA, i.e., 0.09. Even though the initial impact energy of
the second hit is 60J (for octet) and 120J (for Isomax), the absorbed energy of the sandwich
plates do not reach to 60J and 120J due to the failure occurred in the sandwich plates.
Table S.4 presents the deformed Isomax and octet meta-sandwich plates subjected to a
double-hit impact, obtained by experimental tests and predicted by FEA (equivalent stress
distribution is also shown in Fig. S.1). It is seen that cracks and delamination occurred during the
impacts are along the 3D printing directions. Since we overlook the effects of 3D printing
toolpath in FEA, delamination cannot be captured in deformed sandwich plates obtained by
FEA.
Figure S.1: Energy time-history obtained from the first and second hits of impact experimental tests and FEA of
architected meta-sandwich plates subjected to 60J and 120J impacts.
32
Table S.4: Experiment and FEA comparison of Isomax and octet sandwich plates subjected a double-hit impact.
Unit cell Experiment FE simulation
Delamination
Isomax 0.3
Isomax 0.5
Octet 0.3
Crack
Octet 0.5
33
cf cc c
FI f
c
, FI c
c
and FI c
c,max
S.1
f ,max c,max
𝑐 𝑐
where 𝜀𝑓,𝑚𝑎𝑥 , 𝜀𝑐,𝑚𝑎𝑥 and 𝛾𝑐,𝑚𝑎𝑥 represent the allowable compressive strain of the face-sheet,
allowable compressive strain of the core and allowable shear strain of the core, respectively. In
addition, 𝜀𝑓𝑐 , 𝜀𝑐𝑐 and 𝛾𝑐 represent the applied compressive strain of the face-sheet, applied
compressive strain of the core and applied shear strain of the core, respectively. Whenever one of
𝛾
failure indexes (i.e., FIf, 𝐹𝐼𝑐𝜀 and 𝐹𝐼𝑐 ) equals to unity, the sandwich plates fail [53].
a2 a2
N Ncr , S.2
Es t 3 t Es
where 𝐸𝑠 and ρ are Young’s modulus and material density of constitutive solid materials (i.e.,
PLA used for 3D printing meta-sandwich structures). Figure S.2 presents the fundamental
frequency of meta-sandwich plates and non-dimensional buckling loads of meta-sandwich beams
for the span-to-thickness ratios of Ls = 3 (7×1×1 unit cells) and Ls = 1.8 (7×2×2 unit cells). As
shown in Fig. S.2a, the natural frequency of octet meta-sandwich plate is the maximum and
cubic meta-sandwich plate is the minimum among three meta-sandwich plates for the relative
densities of ρ = 30% and 50%. Figures S.2b and S.2c show that the buckling loads of octet meta-
sandwich beam along its length (x-axis) are higher than those of Isomax and cubic meta-
sandwich beams for Ls = 3 and ρ = 50% or Ls = 3 and ρ = 30%. Therefore, it is seen that the
global behavior of the sandwich plate with the same architectures and geometry in comparison to
other sandwich plates could be changed due to the relative density. It should be noted that the
boundary condition to obtain the natural frequency and buckling loads are simply supported and
fixed-free, respectively.
34
Figure S.2: Structural analysis of architected meta-sandwich structures: (a) Fundamental frequency of sandwich
plates, (b) and (c) Non-dimensional buckling loads of sandwich beams with the span-to-thickness ratios of Ls = 1.8
and 3, respectively.
Figure S.3: In-plane rotated cubic cells are used in FE modeling of architected meta-sandwich beams.
35
S6. Dynamic Energy Absorption of Meta-sandwich Plate: Comparison of FEA Results and
Experimental Data
Table S.5 presents the comparison of energy absorption percentage of meta-sandwich plates
with the relative densities of ρ = 30% and 50% subjected to 3J and 40J impacts evaluated by the
experiments and FEA. The maximum difference between experimental data and FEA predictions
is less than 5%.
Table S.5: Comparison of FEA results and experimental data for impact energy absorption of meta-sandwich plates.
Energy absorption percentage Energy absorption percentage
Core architecture (3J impact) (40J impact)
FEA Experiment FEA Experiment
Isomax 72.05 70.31 86.02 83.52
ρ = 30% Octet 70.98 69.18 84.97 82.19
Cubic 70.08 68.74 82.13 80.96
Isomax 71.54 69.91 81.74 79.11
ρ = 50% Octet 74.09 72.99 91.45 90.13
Cubic 73.65 72.09 74.79 72.02
36