3D Printed Polymer Core and Carbon Fiber Skin Sandwich Composite: An Alternative Material and Process for Electric Vehicles Customization

Abstract

3D Printing is a promising technology that can create a product quickly. It is good to create products in small quantities with a high degree of geometry complexity. However, its mechanical properties are relatively low. On the other hand, composite technology offers the ability to create a product with relatively large dimensions, and a high strength-to-weight ratio, and can be designed according to its application. In a large dimensional composite product, to add their bending rigidity properties, a core layer such as a honeycomb is used; it is called a sandwich composite. Making composite products in small numbers such as product modification or customization is relatively expensive in terms of material, labor, and processing time. The process begins with designing, making patterns, making molds, fabricating, and finishing products. In this study, a breakthrough in making sandwich composite can eliminate those steps. The result of this study showed that the bending rigidity properties of the sandwich composite were influenced by the mechanical properties of the core, core dimensions, and the parameters of the 3D printing process. Considering the advantages of geometry complexity, the advantages of mechanical properties, and the flexibility of composite, sandwich composites are suitable for modification or customization of electric vehicle components.