Designing lightweight 3D-printable bioinspired structures for enhanced compression and energy absorption properties

Journal article

Harish, A., A. Alsaleh, N., Ahmadein, M., Elfar, A., Djuansjah, J., Hassanin, H., El-Sayed, M. and Essa, K. 2024. Designing lightweight 3D-printable bioinspired structures for enhanced compression and energy absorption properties. Polymers. 16 (6), p. 729. https://doi.org/10.3390/polym16060729
AuthorsHarish, A., A. Alsaleh, N., Ahmadein, M., Elfar, A., Djuansjah, J., Hassanin, H., El-Sayed, M. and Essa, K.
Abstract

Recent progress in additive manufacturing, also known as 3D printing, has offered several benefits, including high geometrical freedom and the ability to create bioinspired structures with intricate details. Mantis shrimp can scrape the shells of prey molluscs with its hammer-shaped stick, while beetles have highly adapted forewings that are lightweight, tough, and strong. This paper introduces a design approach for bioinspired lattice structures by mimicking the internal microstructures of a beetle’s forewing, a mantis shrimp’s shell, and a mantis shrimp’s dactyl club, with improved mechanical properties. Finite element analysis (FEA) and experimental characterisation of 3D printed polylactic acid (PLA) samples with bioinspired structures were performed to determine their compression and impact properties. The results showed that designing a bioinspired lattice with unit cells parallel to the load direction improved quasi-static compressive performance, among other lattice structures. The gyroid honeycomb lattice design of the insect forewings and mantis shrimp dactyl clubs outperformed the gyroid honeycomb design of the mantis shrimp shell, with improvements in ultimate mechanical strength, Young’s modulus, and drop weight impact. On the other hand, hybrid designs created by merging two different designs reduced bending deformation to control collapse during drop weight impact. This work holds promise for the development of bioinspired lattices employing designs with improved properties, which can have potential implications for lightweight high-performance applications.

KeywordsAdditive manufacturing; Bio-inspired design; Lattice structure; Energy absorption; Light-weight aerospace structures
Year2024
JournalPolymers
Journal citation16 (6), p. 729
PublisherMDPI
ISSN2073-4360
Digital Object Identifier (DOI)https://doi.org/10.3390/polym16060729
Official URLhttps://www.mdpi.com/2073-4360/16/6/729
Publication dates
Print07 Mar 2024
Publication process dates
Accepted01 Mar 2024
Deposited20 Mar 2024
Accepted author manuscript
File Access Level
Restricted
Publisher's version
License
File Access Level
Open
Output statusPublished
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Fan , W., Chen, Y., Li, J., Sun, Y., Feng, F., Hassanin, H. and Sareh, P. 2021. Machine learning applied to the design and inspection of reinforced concrete bridges: Resilient methods and emerging applications. Structures. 33, pp. 3954-3963. https://doi.org/10.1016/j.istruc.2021.06.110
Porosity, cracks, and mechanical properties of additively manufactured tooling alloys: A review
Bidare, P., Jiménez, A., Hassanin, H. and Essa, K. 2021. Porosity, cracks, and mechanical properties of additively manufactured tooling alloys: A review. Advances in Manufacturing. https://doi.org/10.1007/s40436-021-00365-y
Laser powder bed fusion of Ti-6Al-2Sn-4Zr-6Mo alloy and properties prediction using deep learning approaches
Hassanin, H., Zweiri, Y., Finet, L., Essa, K., Qiu, C. and Attallah, M. 2021. Laser powder bed fusion of Ti-6Al-2Sn-4Zr-6Mo alloy and properties prediction using deep learning approaches. Materials. 14 (8), p. 2056. https://doi.org/10.3390/ma14082056
3DP printing of oral solid formulations: a systematic review
Brambilla, C., Okafor-Muo, O., Hassanin, H. and ElShaer, A. 2021. 3DP printing of oral solid formulations: a systematic review. Pharmaceutics. 13 (3), p. 358. https://doi.org/10.3390/pharmaceutics13030358
Powder-based laser hybrid additive manufacturing of metals: A review
Hassanin, H. 2021. Powder-based laser hybrid additive manufacturing of metals: A review. The International Journal of Advanced Manufacturing Technology.
Micro-fabrication of ceramics: additive manufacturing and conventional technologies
Hassanin, H., Essa, K., Elshaer, A., Imbaby, M. and El-Sayed, T. E. 2021. Micro-fabrication of ceramics: additive manufacturing and conventional technologies. Journal of Advanced Ceramics. 10, pp. 1-27. https://doi.org/10.1007/s40145-020-0422-5
4D Printing of origami structures for minimally invasive surgeries using functional scaffold
Langford, T, Mohammed, A., Essa, K., Elshaer, A. and Hassanin, H. 2020. 4D Printing of origami structures for minimally invasive surgeries using functional scaffold. Applied Sciences. 11 (1), p. 332. https://doi.org/10.3390/app11010332
Reconfigurable multipoint forming using waffle-type elastic cushion and variable loading profile
Hassanin, H., Mohammed, M., Abdel-Wahab, A. and Essa, K 2020. Reconfigurable multipoint forming using waffle-type elastic cushion and variable loading profile. Materials.
3D printing of solid oral dosage forms: numerous challenges with unique opportunities
Hassanin, H. 2020. 3D printing of solid oral dosage forms: numerous challenges with unique opportunities. Journal of Pharmaceutical Sciences. https://doi.org/10.1016/j.xphs.2020.08.029
Design optimisation of additively manufactured titanium lattice structures for biomedical implants
El-Sayed, M.A., Essa, K., Ghazy, M. and Hassanin, H. 2020. Design optimisation of additively manufactured titanium lattice structures for biomedical implants. The International Journal of Advanced Manufacturing Technology. https://doi.org/10.1007/s00170-020-05982-8
4D Printing of NiTi auxetic structure with improved ballistic performance
Hassanin, H., Abena, A., Elsayed, M.A. and Essa, K. 2020. 4D Printing of NiTi auxetic structure with improved ballistic performance. Micromachines. 11 (8), p. 745. https://doi.org/doi.org/10.3390/mi11080745