Izod impact resistance of 3D printed discontinuous fibrous composites with Bouligand structure

The Bouligand structure found in the dactyl club of mantis shrimps is known for its impact resistance. However, Bouligand-inspired reinforced composites with 3D shapes and impact resistance characteristics have not yet been demonstrated. Herein, direct ink writing was used to 3D print composites reinforced with glass microfibers assembled into Bouligand structures with controllable pitch angles. The energy absorption levels of the Bouligand composites under impact were found to surpass those of composites with unidirectional microfiber alignment. Additionally, the Bouligand composites with a pitch angle of 40° exhibited a maximum energy absorption of 2.4 kJ/m², which was 140% higher than that of the unidirectional composites. Furthermore, the characterization of the topography of the fractured surface, supplemented with numerical simulations, revealed a combination of crack twisting and crack bridging mechanisms. Flexural tests conducted on the composites with a pitch angle of 40° revealed that these composites had the strongest properties, including a flexural strength of 36.9 MPa, a stiffness of 2.26 GPa, and energy absorption of 8 kJ/m². These findings are promising for the microstructural design of engineered composites using direct ink writing for applications in aerospace, transportation, and defense.