Compression Behavior of 3D Printed Composite Isogrid Structures

Composite materials, particularly carbon fiber-reinforced polymers (CFRPs), have become a cornerstone in industries requiring high-performance materials due to their exceptional mechanical properties, such as high strength-to-weight ratios, and their inherent lightweight nature. These attributes make CFRPs highly desirable in aerospace, automotive, and other advanced engineering applications. However, the compressive behavior of CFRP structures remains a challenge, primarily due to the material sensitivity to structural instability, leading to matrix cracking and premature failure under compressive loads. Isogrid structures, characterized by their unique geometric patterns, have shown promise in enhancing the compressive behavior of CFRP panels by providing additional support that mitigates these issues. Traditionally, these structures are manufactured using automated techniques like automated fiber placement (AFP) and automated tape laying (ATL), which, despite their efficacy, are often cost-prohibitive for small-scale or custom applications. Recent advancements in 3D-printing technology, particularly those involving continuous fiber reinforcement, present a cost-effective and flexible alternative for producing complex CFRP structures. This study investigates the compressive behavior of 3D-printed isogrid structures, fabricated using continuous carbon fiber reinforcement via an Anisoprint Composer A3 printer equipped with towpreg coextrusion technology. A total of eight isogrid panels with varying infill percentages were produced and subjected to buckling tests to assess their performance. The experimental results indicate a direct correlation between infill density and buckling resistance, with higher infill densities leading to increased buckling loads. Additionally, the failure modes were observed to shift from local to global buckling as the infill density increased, suggesting a more uniform distribution of compressive stresses. Post-test analyses using optical microscopy and scanning electron microscopy (SEM) revealed the presence of voids within the 3D-printed structures, which were found to negatively impact the mechanical performance of the isogrid panels. The findings of this study demonstrate that 3D-printed isogrid CFRP structures can achieve significant buckling resistance, making them a viable option for high performance applications. However, the presence of voids remains a critical issue, highlighting the need for process optimizations in 3D-printing techniques to enhance the overall performance and reliability of these structures.