Hybrid lattice structure with micro graphite filler manufactured via additive manufacturing and growth foam polyurethane

The utilisation of lightweight structures is a common practice across a range of disciplines, including the construction of light steel frames, sandwich panels, and transportation infrastructure, among others. The advantages of lightweight structures include design flexibility, weight reduction, and the sustainability of materials that can be easily recycled. However, these advantages also present significant weaknesses. Compared to solid materials with compact weight, lightweight structures do not have the same characteristics. With the reduction in material weight, the strength of the lightweight structure decreases significantly compared to solid materials. In this study, the lightweight structure was made using additive manufacturing and reinforced with solid Composite Polyurethane Foam reinforced with graphite filler expanded into the lightweight structure. The results showed that in the compression test, the mixture with 2 % graphite filler had the highest value of 2.5 kN. The highest hardness test on the specimen with a 2 % graphite mixture was 19.8 HA. FT-IR testing showed that the carbon bonds from graphite in the 2 % specimen had the highest intensity. The test results showed that the addition of Polyurethane Foam into the structure could enhance material strength effectively without adding significant material weight.