Stress concentration targeted reinforcement using multi-material based 3D printing

Topological engineering (3D printing into complex geometry) has emerged as a pragmatic approach to develop high specific strength (high strength and low density) lightweight structures. These complex lightweight structures fail at high-stress concentration regions, which can be, replaced with soft/tough material using 3D printing. It can improve mechanical properties such as strength, toughness and energy absorption etc. Here, we have developed stress concentration targeted multi-material schwarzite structures by 3D printing technique. The soft (Thermoplastic Polyurethane) material is reinforced at high-stress concentration regions of hard (Polylactic acid) schwarzite structures to enhance the specific yield strength and resilience. The mechanical properties and responses of these structures were then assessed via uniaxial compression tests. The multi-materials 3D printed composite structure shows improved mechanical properties compared to single materials architecture. The specific resilience of composites demonstrates remarkable enhancements, with percentage increases of 204.70 %, 596.50 %, and 1530.99 % observed when compared to hard primitives, and similarly impressive improvements of 182.45 %, 311.64 %, and 477.75 % observed in comparison to hard gyroids. The obtained experimental findings were comprehensively examined and validated with molecular dynamics (MD) simulations. The promising characteristics of these lightweight multi-material-based Schwarzites structures can be utilized in various fields such as energy harvesting devices, protective, safety gears, and aerospace components.