Enhancing Mechanical Energy Absorption of Honeycomb and Triply Periodic Minimal Surface Lattice Structures Produced by Fused Deposition Modelling in Reusable Polymers

This study investigated the mechanical energy absorption properties of polymeric lattice structures fabricated using additive manufacturing. Existing studies have primarily focused on rigid or single-use materials, with limited attention given to flexible polymers and their behaviour under repeated compressive loading. Addressing this gap, the structures investigated in this study are manufactured using three flexible polymers-polyether block amide, thermoplastic polyurethane, and thermoplastic copolyester elastomer-to enhance the reusability performance. Two high-performance designs were analysed, namely honeycomb structures (inspired by pomelo peel and simply hexagonal arrangements) and 3D triply periodic minimal surface structure of the type FRD. The primary objective was to evaluate their energy absorption capacity and reusability using three repeated compression tests. These tests revealed that thermoplastic copolyester elastomer exhibited the highest energy absorption in initial impact conditions, but lower values for the following compressions. However, polyether block amide demonstrated superior reusability, maintaining a consistent energy absorption efficiency of 56.1% over multiple compression cycles. The study confirms that modifying triply periodic minimal surface structures along the z-axis enhances their absorption efficiency, with even-numbered z-parameter structures outperforming odd-numbered ones due to their complete cell structure. These findings highlight the critical role of structural geometry and material selection to optimise polymeric lattice structures for lightweight reusable energy absorption applications, such as automotive safety and impact protection.