Experimental investigation on impact resistance of stacked composite material hybridization by 3D printed CF-PEEK and aluminium foils

This study presents a comprehensive experimental investigation into the impact resistance of stacked composite structures fabricated by hybridizing 3D-printed carbon fiber-reinforced polyether ether ketone (CF-PEEK) with perforated aluminum (Al 3004) foil layers. Both perforated and unperforated Al foil, strategically interleaved within CF-PEEK layers and bonded using epoxy resin. Two critical fabrication parameters fiber orientation (0°, 45°, and 90°) and layer height (0.2 mm, 0.3 mm, and 0.4 mm) were systematically varied using a full factorial design to assess their influence on impact performance. Charpy impact tests were conducted in accordance with ASTM D6110 on both hybrid CF-PEEK/Al foil laminates and CF-PEEK-only specimens. Results indicated a substantial improvement in impact energy absorption and impact strength for the hybrid configurations, with peak values reaching up to 30 J and 402.2 J/m², respectively at a fiber orientation of 90° and a layer height of 0.2 mm. In contrast, corresponding CF-PEEK-only specimens exhibited significantly lower energy absorption, with maximum values of 17 J and 227.9 J/m² under the same conditions. Among all parameter combinations, the hybrid specimens with a fiber orientation of 45° and a layer height of 0.3 mm demonstrated the most consistent and enhanced performance. These findings highlight the synergistic effect of metallic reinforcement and optimized printing parameters improves mechanical robustness of additively manufactured composite laminates. This work emphasizes the potential of hybrid additive manufacturing (HAM) approaches in developing lightweight, high-strength materials for aerospace, defense, and impact-critical applications, offering a promising pathway for tailoring structural performance through designable interfacial architectures and controlled fabrication parameters.