Energy Absorption and Stiffness of Thin and Thick-Walled Closed-Cell 3D-Printed Structures Fabricated from a Hyperelastic Soft Polymer

This study analyses the energy absorption and stiffness behaviour of 3D-printed supportless, closed-cell lattice structures. The unit cell design is bioinspired by the sea urchin morphology having organism-level biomimicry. This gives rise to an open-cell lattice structure that can be used to produce two different closed-cell structures by closing the openings with thin or thick walls, respectively. In the design phase, the focus is placed on obtaining the same relative density with all structures. The present study demonstrates that closure of the open-cell lattice structure enhances the mechanical properties without affecting the functional requirements. Thermoplastic polyurethane (TPU) is used to produce the structures via additive manufacturing (AM) using fused filament fabrication (FFF). Uniaxial compression tests are performed to understand the mechanical and functional properties of the structures. Numerical models are developed adopting an advanced material model aimed at studying the hysteretic behaviour of the hyperelastic polymer. The study strengthens design principles for closed-cell lattice structures, highlighting the fact that a thin membrane is the best morphology to enhance structural properties. The results of this study can be generalised and easily applied to applications where functional requirements are of key importance, such as in the production of lightweight midsole shoes.