Process development and compression behavior of innovative 3D bi-directional flat-knitted spacer-reinforced composites

3D knitted fabrics are regarded as a viable option for advanced composite materials. Flat-knitted spacer fabrics (FKSF) which are in the category of 3D knitted structures have attracted many attentions due to outstanding characterizations such as high formability and good impact behavior. These structures consist of two surface layers which are linked together by multiple knitted connecting layers. Despite the merits of 3D-FKSFs as composite reinforcements, they have some structural restrictions such as limited thickness. This study aims to develop and characterize bi-directional 3D knitted spacer structures which could be replaced with conventional FKSFs. In the developed structures, the upper and lower surface layers are connected together by two truncated pyramids which can be configurated in any dimensions using an innovative knitting technique. For providing a report regarding their compression behavior, these 3D structures were produced in two different thicknesses on an electronic flat knitting machine. Then, they were impregnated with epoxy resin via vacuum resin transfer molding and the cured composites were subjected to compression force. The results revealed that their compression behavior is similar to the behavior of conventional honey-comb sandwich structures.