A novel ultra-lightweight lattice manufacturing method with continuous carbon fiber reinforced peek

Abstract

Lattice structures, characterized by repeating cellular units, find widespread applications. Especially in aerospace, automotive, infrastructural, and medical sectors, lattice structures are utilized due to their lightweight nature, exceptional energy absorption, superior thermal/acoustic insulation, and ultra-high specific strength. However, their complex geometries pose significant manufacturing challenges. The growing utilization of additive manufacturing has led to extensive exploration of various lattice structures and materials. Lattice structures manufactured with various additive manufacturing platforms were extensively investigated in the literature. Still, their comparatively low mechanical properties remain a limiting factor because of the inherent problems of additive manufacturing, such as low interlayer bonding and porosity. Therefore, this study introduces a novel method employing continuous carbon fiber-reinforced thermoplastic (CFRTP) filaments comprising 50% Vf for lattice structure fabrication. These filaments consist of carbon fiber and a poly ether ether ketone thermoplastic matrix. These filaments were integrated into molds produced via VAT photopolymerization to create pyramid lattice configurations. Compression tests conducted on the resulting lattice structures demonstrated their capacity to withstand approximately 500 N of compression force while weighing only 0.075 g of lattice strut. This outcome highlights the substantial specific strength achieved through this innovative lattice manufacturing technique. The findings contribute to advancing the utilization of CFRTP-based lattice structures, promising lightweight, high-strength structural components across various applications.