Mechanical Characteristics of Sandwich Structures with 3D-Printed Bio-Inspired Gyroid Structure Core and Carbon Fiber-Reinforced Polymer Laminate Face-Sheet

Abstract

The gyroid structure is a bio-inspired structure that was discovered in butterfly wings. The geometric design of the gyroid structure in butterfly wings offers a unique combination of strength and flexibility. This study investigated sandwich panels consisting of a 3D-printed gyroid structure core and carbon fiber-reinforced polymer (CFRP) facing skin. A filament fused fabrication 3D printer machine was used to print the gyroid cores with three different relative densities, namely 10%, 15%, and 20%. Polylactic acid (PLA) was used as the printing material for the gyroid. The gyroid structure was then sandwiched and joined by an epoxy resin between CFRP laminates. Polyurethane foam (PUF) was filled into the gyroid core to fill the cavity on the core for another set of samples. Flexural and compression tests were performed on the samples to investigate the mechanical behavior of the sandwiches. Moreover, the two-parameter Weibull distribution was used to evaluate the results statistically. As a result, the sandwich-specific facing stress and core shear strength from the three-point bending test of the composites increased with the increase in sandwich density. Core density controls the flexural characteristics of the sandwich. Adding PUF improves the deflection at the maximum stress and the sustained load after fracture of the sandwich. Compression strength, modulus, and energy absorbed by gyroid core sandwiches and their specific properties are higher than the PUF-filled gyroid core sandwiches at equal sandwich density.