Energy absorption properties of a 3D-printed lattice-core foam composite under compressive and low-velocity impact loading

This experimental work aims to investigate the compression and low-velocity impact characteristics of different lattice structures made via Fused Deposition Modeling (FDM) technology to be used as a skeleton of a lightweight polyurethane foam (PUF) composite. Three frame-unit geometries, namely one cubic cell and two pyramidal cell variants, were firstly considered as reinforcement. A stepwise design rationale was adopted to identify better lattice configurations progressively, focusing on manufacturing aspects such as cell geometry and structural density, as well as efficiency requirements. A square-based pyramid geometry was identified as the most efficient in energy dissipation and, therefore, was selected for further investigations, varying bulk density, to identify the lattice reinforcement to be embedded in the polyurethane foam matrix and generate the PUF composite. The experimental outcomes showed enhanced dissipative capacity of the composite structure under static and dynamic loading conditions, suggesting promising applications to preserve the integrity of objects in accidental collisions.