Functionally graded multi-morphology lattice structures as an optimized sandwich core via digital light processing additive manufacturing

This investigation aims to present a high-strength sandwich core with functionally graded multi-morphology lattice inner structures through vat photo-polymerization additive manufacturing (AM). The five better strut-based designs based on [1], are considered here. All printed specimens have been fabricated from photopolymer resin to ensure manufacturability in a digital light processing (DLP) 3D printer. Firstly, the resin and structural characteristics have been examined. Simultaneously, the lattice core is divided into three regions based on the von Mises stress distribution and tensile and compression responses in finite element analysis (FEA). Based on the mechanical responses of the beam-based structures, these topologies have been applied in each region in an optimal fixed relative density distribution, considering different steps and types. This proposed technique is numerically investigated and experimentally validated using a three-point bending test. As a result, the optimized core demonstrated a 96% increase in maximum fracture force and a 174% increase in stiffness compared to the homogeneous body. Additionally, it exhibited a different deformation mode than the single morphology under similar conditions. These significant findings indicate that this approach provides a new perspective on a high-strength design involving more than three morphologies, and it is faster than computational topology optimization processes.