Infill strategies for improving the impact behavior of polymer composites utilizing statistical and thermal analysis

The emergence of additive manufacturing has enabled scientists to efficiently construct complex geometric forms, facilitating the creation of robust structures with enhanced resistance to external forces. Fused filament fabrication (FFF) enables the attainment of personalization, enhanced design flexibility, waste reduction, expedited prototyping, and the generation of intricate profiles. In this study, an impact test was conducted to measure the energy absorption of polymer composites fabricated through fused filament deposition. Specifically, the composites investigated were poly-lactic acid reinforced with multi-walled carbon nanotubes, carbon fibers, and graphene. The study examined the effects of different infill patterns and infill densities on the energy absorption capabilities of these composites. The utilization of a gyroid infill pattern with a 100% infill density has been found to demonstrate the highest level of energy absorption in the context of graphene-reinforced poly-lactic acid. In order to examine the relationship between the given process parameters and the energy-absorbing behavior, an analysis of variance using Taguchi’s approach is employed on the impact test findings. The examination of fractured surfaces using scanning electron microscopy (SEM) unveiled several types of voids, exhibiting enhanced interlayer adhesion in distinct composite materials. The thermal characteristics of the composite material were determined by the utilization of differential scanning calorimetry (DSC) analysis. The experimental results demonstrate that polymer composites have future potential to be employed in automotive parts that necessitate high impact resistance, such as the fabrication of bumpers and body panels.