Photocurable Foam for Three-Dimensional-Printed Porous Structures.

In this research, a foam three-dimensional (3D) printing method using digital light processing (DLP) technology was developed to fabricate 3D-printed porous structures. To address the challenges in preparing DLP precursor foam fluid, we designed a specialized foaming device. This device enables the precursor solution to be blended with air, resulting in a stable foam precursor with an adjustable air/liquid fraction and suitable fluidity, crucially enhancing the gas-liquid contact time for the printing process. By manipulation of fluid flow rates, cycle counts, and gas/liquid ratios, one can easily prepare uniform foams with precise control over the pore size and porosity. To avoid significant volume reduction during ultraviolet (UV) curing, nanoparticle fillers were introduced into the network to prevent collapse of the foam structure. Furthermore, the inclusion of an UV absorber enhanced the quality of the printing process by addressing the limitations associated with particle scattering and reflection. The DLP process can readily fabricate intricate structures, featuring a planar resolution below 30 µm and a printing accuracy of less than 1%. Several examples were also demonstrated to highlight the advantages of this technology and its ability to directly print custom foam structures, thereby saving time and material resources.

Neural Network-Based Surrogate Modeling for Buckling Performance Optimization of Lightweight-Composite Collapsible Tubular Masts.

The collapsible tubular mast (CTM) can be compactly folded for transport and deployed in orbit to serve as a key structural element. Once deployed, the CTM is vulnerable to buckling under axial load and bending moments, compromising its load-bearing capacity. The intricate relationship between the CTM's cross-section and its buckling behavior poses a significant challenge for designers. This is due to the ultra-thin nature of the CTM, which gives rise to highly localized buckling modes rather than global ones. To overcome this challenge, we developed surrogate models using a neural network (NN) trained with data from finite element analysis (FEA). These NN-based surrogate models provide high computational accuracy in predicting nonlinear buckling loads under axial force and bending moments around the two principal axes of the CTM's cross-section, achieving R2 values of 0.9906, 0.9987, and 0.9628, respectively. These models also significantly improve computational efficiency, reducing prediction time to a fraction of a second compared to several minutes with FEA. Furthermore, the NN-based surrogate models enable the usage of the non-dominated sorting genetic algorithm (NSGA-II) for multi-objective optimization (MOO) of the CTMs. These models can be integrated in the NSGA-II algorithm to evaluate the objective function of existing and new individuals until a set of 1000 non-dominated solutions, i.e., cross-sectional configurations optimizing buckling performance, is identified. The proposed approach enables the design of ultra-thin CTMs with optimized stability and structural integrity by promoting design decisions based on the quantitative information provided by the NN-based surrogate models.

Non-Conventional Wing Structure Design with Lattice Infilled through Design for Additive Manufacturing.

Lightweight structures with a high stiffness-to-weight ratio always play a significant role in weight reduction in the aerospace sector. The exploration of non-conventional structures for aerospace applications has been a point of interest over the past few decades. The adaptation of lattice structure and additive manufacturing in the design can lead to improvement in mechanical properties and significant weight reduction. The practicality of the non-conventional wing structure with lattices infilled as a replacement for the conventional spar-ribs wing is determined through finite element analysis. The optimal lattice-infilled wing structures are obtained via an automated iterative method using the commercial implicit modeling tool nTop and an ANSYS workbench. Among five different types of optimized lattice-infilled structures, the Kelvin lattice structure is considered the best choice for current applications, with comparatively minimal wing-tip deflection, weight, and stress. Furthermore, the stress distribution dependency on the lattice-unit cell type and arrangement is also established. Conclusively, the lattice-infilled structures have shown an alternative innovative design approach for lightweight wing structures.

Effect of the Material Extrusion Process Parameters on the Compressive Properties of Additively Manufactured Foamed and Nonfoamed Polylactic Acid Structures.

This work evaluates the potential for foamable polymer filaments to be used to make lightweight, energy-absorbing structures using additive manufacturing. To achieve this, a commercial, foamable polylactic acid filament was extruded using a material extrusion process to make parts for compression testing. It was found that a maximum foam expansion could be achieved at an extrusion nozzle temperature of 220°C, but that to achieve dimensional accuracy, the material flow rate through the nozzle had to be adjusted by decreasing the extrusion multiplier value. In a novel approach, accurate and faster builds could be achieved by decreasing the infill instead. When compared with porous structures achieved by using partial infilling instead or as well as foaming, all materials were found to follow the same power-law function of the solid fraction. These trends indicated that the mechanical response was, within experimental scatter, a function of the overall solid fraction and not influenced by whether the porosity was within or between the raster lines. Although there was no apparent benefit to the mechanical performance in introducing porosity into a polymer by foaming, foamable filaments are desirable if stiff, lightweight structures with low fractions of interconnected porosity are required and can be used in combination with infilling to produce low-density structures that would be highly suitable for cores in novel lightweight sandwich structures.

FlaxPack: Tailored Natural Fiber Reinforced (NFRP) Compliant Folding Corrugation for Reversibly Deployable Bending-Active Curved Structures.

As the use of Natural Fiber Reinforced Polymers (NFRPs) become increasingly popular in the built environment, steps in established workflows, including molding and transportation, continue to impose constraints on what is possible in the material's fabrication process. This research builds on previous studies of moldless fiber composites using tailored fiber placement (TFP) as a fabrication method. By integrating compliant folding mechanisms into the flat preform to give shape to the final desired geometry this research replaces all dependencies on molds and formworks during the resin curing process with programmed formal deformations. The desired geometry is digitally simulated from its two-dimensional state into its resultant three-dimensional state and then subsequently structurally analyzed. The flat pack components are material efficient and can be transported flat to the site for their final assembly into their programmed geometry. This form is locked into its bent active state through the use of a simple drawstring that can later be removed to revert the form back into its flat state. This method is demonstrated through the digital fabrication of a stool where flat-packed elements can be deployed into elegant solutions that embody structure, material, and form simultaneously.

Optimal Design of Bubble Deck Concrete Slabs: Serviceability Limit State.

In engineering practice, one can often encounter issues related to optimization, where the goal is to minimize material consumption and minimize stresses or deflections of the structure. In most cases, these issues are addressed with finite element analysis software and simple optimization algorithms. However, in the case of optimization of certain structures, it is not so straightforward. An example of such constructions are bubble deck ceilings, where, in order to reduce the dead weight, air cavities are used, which are regularly arranged over the entire surface of the ceiling. In the case of these slabs, the flexural stiffness is not constant in all its cross-sections, which means that the use of structural finite elements (plate or shell) for static calculations is not possible, and therefore, the optimization process becomes more difficult. This paper presents a minimization procedure of the weight of bubble deck slabs using numerical homogenization and sequential quadratic programming with constraints. Homogenization allows for determining the effective stiffnesses of the floor, which in the next step are sequentially corrected by changing the geometrical parameters of the floor and voids in order to achieve the assumed deflection. The presented procedure allows for minimizing the use of material in a quick and effective way by automatically determining the optimal parameters describing the geometry of the bubble deck floor cross-section. For the optimal solution, the concrete weight of the bubble deck slab was reduced by about 23% in reference to the initial design, and the serviceability limit state was met.

On the Mechanical Behaviour of Biomimetic Cornstalk-Inspired Lightweight Structures.

This paper presents an investigation on the stiffness and energy absorption capabilities of three proposed biomimetic structures based on the internal architecture of a cornstalk. 3D printing was used to manufacture specimens using a tough and impact-resistant thermoplastic material, acrylonitrile butadiene styrene (ABS). The structural stiffness, maximum stress, densification strain, and energy absorption were extracted from the compression tests performed at a strain rate of 10-3 s-1. A numerical model was developed to analyse the behaviour of the biomimetic structures under compression loading. Further, a damage examination was conducted through optical microscopy and profilometry. The results showed that the cornstalk-inspired biomimetic structure exhibited a superior specific energy absorption (SEA) capability that was three times higher than that of the other core designs as reported in the literature.

Dynamic Deformation and Perforation of Ellipsoidal Thin Shell Impacted by Flat-Nose Projectile.

Experimental and theoretical studies were carried out on the dynamic deformation and penetration response characteristics of metal ellipsoidal thin curved shells under impact loads. The deformation characteristics of the impacted ellipsoid shell was investigated via the use of a light gas gun to carry out impact loading experiments at different speeds. Ten cases of experiments were conducted with the impact velocities distributed between 25.69 m/s and 118.97 m/s. Stereo digital image correlation (3D-DIC) technology was applied to capture the dynamic deformation and penetration process of the impacted shell. The recovered shells were measured, and the deformation characteristics were analyzed, along with the dynamic evolution, as observed through 3D-DIC analysis. Based on the experimental results, the displacement mode was summarized and the displacement distribution of the locally impacted ellipsoid shell was proposed. The governing equations were derived for the dynamic deformation and penetration of the impacted ellipsoid shell by means of the Lagrange equation. The proposed theoretical model was verified based on the experimental results. Finally, the influence of the curvature distribution on the impact resistance of ellipsoidal shells is discussed. The results indicated that the proposed theoretical model was effective in analyzing the large deformation and the penetration speed. Stretching the axial length of the ellipsoid shell in the impact direction improved its resistance to penetration. Stretching the axial length of the ellipsoid shell perpendicular to the impact direction improved its resistance to deformation, but reduced its resistance to penetration. Maintaining the triaxial ratio and appropriately reducing the size of the ellipsoidal shell improved its resistance to both deformation and penetration. The above research provides a reference for the analysis of the impact resistance of thin-walled curved shell structures in engineering.

Algorithmic-Aided Approach for the Design and Evaluation of Curvilinear Steel Bar Structures of Unit Roofs.

Rationalization in structural design in the field of steel structures mostly consists inreducing structural material. The aim of this work was to develop an algorithmic-aided, original and practical approach to shaping curvilinear steel bar structures of modular roofs, enabling their optimization. The first stage of shaping consists in creating algorithms that define the structures of shelters made of four roof units. Algorithmic definitions of the structures made it possible to obtain many variants of the roof structures with the adopted preliminary criteria. In order to evaluate the effectiveness of the individual variants, the genetic optimizations of the structures' forms were carried out. Assuming that the structures were loaded with self-weights, the cross-sections of the structures' members were optimized with the permissible deflections, while the structures' weights were the optimization criteria. This allowed us to eliminate the design variants unfavorable in terms of shape and weight. In contrast, the structures with the most advantageous properties were then optimized for weight under snow and wind loads. The research allowed us to notice how the shapes of the structures influenced their efficiency. The dual approach proposed for shaping, which takes advantage of the generative design and consistent flow of information during shaping, allowed us to achieve better solutions compared to the traditional approach.

Different Approaches for Manufacturing Ti-6Al-4V Alloy with Triply Periodic Minimal Surface Sheet-Based Structures by Electron Beam Melting.

Targeting biomedical applications, Triply Periodic Minimal Surface (TPMS) gyroid sheet-based structures were successfully manufactured for the first time by Electron Beam Melting in two different production Themes, i.e., inputting a zero (Wafer Theme) and a 200 µm (Melt Theme) wall thickness. Initial assumption was that in both cases, EBM manufacturing should yield the structures with similar mechanical properties as in a Wafer-mode, as wall thickness is determined by the minimal beam spot size of ca 200 µm. Their surface morphology, geometry, and mechanical properties were investigated by means of electron microscopy (SEM), X-ray Computed Tomography (XCT), and uniaxial tests (both compression and tension). Application of different manufacturing Themes resulted in specimens with different wall thicknesses while quasi-elastic gradients for different Themes was found to be of 1.5 GPa, similar to the elastic modulus of human cortical bone tissue. The specific energy absorption at 50% strain was also similar for the two types of structures. Finite element simulations were also conducted to qualitatively analyze the deformation process and the stress distribution under mechanical load. Simulations demonstrated that in the elastic regime wall, regions oriented parallel to the load are primarily affected by deformation. We could conclude that gyroids manufactured in Wafer and Melt Themes are equally effective in mimicking mechanical properties of the bones.

Fatigue Life Estimation with Mean Stress Effect Compensation for Lightweight Structures-The Case of GLARE 2 Composite.

This paper describes the current state-of-the-art in fatigue life assessment for lightweight composite structures with the use of the frequency domain fatigue life calculation method. Random stationary gaussian loading signals have been generated and served in the process of fatigue calculation. The material information that is being used in the calculation process has been obtained from literature for the Glare 2 composite. The effect of nonzero mean stress and different fiber orientations have been taken into account. The calculations have been performed for two mean stress compensation models by Goodman and Gerber. The proposed procedure gives satisfying results for the high-cycle fatigue region for Goodman and an overall good comparison in both regimes for the Gerber model.

Physio-Microstructural Properties of Aerated Cement Slurry for Lightweight Structures.

Cementitious composites, including ferrocement and continuous fiber reinforced cement, are increasingly considered for building construction and repair. One alternative in processing of these composites is to infiltrate the reinforcement (continuous fibers or chicken mesh) with a flowable cementitious slurry. The relatively high density of cementitious binders, when compared with polymeric binders, are a setback in efforts to introduce cementitious composites as lower-cost, fire-resistant, and durable alternatives to polymer composites. Aeration of the slurry is an effective means of reducing the density of cementitious composites. This approach, however, compromises the mechanical properties of cementitious binders. An experimental program was undertaken in order to assess the potential for production of aerated slurry with a desired balance of density, mechanical performance, and barrier qualities. The potential for nondestructive monitoring of strength development in aerated cementitious slurry was also investigated. This research produced aerated slurries with densities as low as 0.9 g/cm³ with viable mechanical and barrier qualities for production of composites. The microstructure of these composites was also investigated.

Microstructure Design of Lightweight, Flexible, and High Electromagnetic Shielding Porous Multiwalled Carbon Nanotube/Polymer Composites.

Multiwalled carbon nanotube/polymer composites with aligned and isotropic micropores are constructed by a facile ice-templated freeze-drying method in a wide density range, with controllable types and contents of the nanoscale building blocks, in order to tune the shielding performance together with the considerable mechanical and electrical properties. Under the mutual promotion of the frame and porous structure, the lightweight high-performance shielding is achieved: a 2.3 mm thick sample can reach 46.7 and 21.7 dB in the microwave X-band while the density is merely 32.3 and 9.0 mg cm-3 , respectively. The lowest density corresponds to a value of shielding effectiveness divided by both the density and thickness up to 104 dB cm2 g-1 , far beyond the conductive polymer composites with other fillers ever reported. The shielding mechanism of the flexible porous materials is further demonstrated by an in situ compression experiment.