Improving flexural performances of fused filament fabricated short carbon fiber reinforced polyamide composites with natural‐inspired structural design

Abstract Both the nacre‐like bionic microstructure and the spiral laminated bionic configuration exhibit superior damage‐tolerance characteristics. On the basis of this observation, the design concept of the bionic helical‐interlayer configuration is innovatively integrated into the design of a bionic nacre‐like honeycomb structure. By systematically studying different spiral angles of honeycomb's interlayer stacking forms, their influence on the structural performance is deeply discussed with four‐point bending tests. Mechanical samples are carefully prepared using short carbon fiber reinforced polyamide composites (i.e., PA6‐CF) through conventional fused filament fabrication (FFF) 3D printing technology, where the accuracy and reliability of the designed bio‐inspired samples are ensured. The experimental results reveal significant improvements in bending strength and elastic modulus across various bionic nacre‐like honeycomb spiral structures compared to uniformly overlap configurations. In particular, the SH‐7.5 sample shows a remarkable 35.47% increase in bending strength and a 65.10% increase in elastic modulus over the SH‐11.25 sample. SEM‐based microstructural analyses are carried out to further explore the fracture mode of the carbon fibers, implied the helical configuration adopted in the nacre‐like honeycomb structure enhances the flexural resistant ability of the PA6‐CF composites. The findings above bear important guiding significance and reference value for the design of lightweight and high damage‐tolerance composite structures. Highlights A novel bio‐inspired structure is implemented to improve the mechanical performance of fused filament fabricated polyamide composites, where the bionic spiral helical configuration is integrated into high‐fracture‐resistance nacre‐like honeycomb structures. Mechanical testing results indicate that a helix angle under 10° results in a significant improvement in the structural performance of flexural strength. Microstructural analysis reveals that the helical configuration enhances the load‐bearing functionality of reinforcing carbon fibers in the printed polyamide composites. FFF 3D printing enables further implementation of the proposed bio‐inspired novel structure for lightweight and damage‐tolerant composite applications with high customization demands.