High-Performance Bionic Architectures via 3D Printing of Recycled Kevlar: A Study of Laser Ablation and Mechanical Properties

ABSTRACTThe study investigates the potential of 3D printing as an eco‐friendly and cost‐effective method to repurpose waste fabrics into valuable products. It explores the use of bio‐inspired structures in 3D printing to gain insights into sandwich structures' mechanical properties and laser ablation characteristics. By incorporating natural skeleton designs such as nacreous and foliated hierarchies and industrial waste material (KF), the research aims to enhance mechanical performance, laser ablation characteristics, and sustainable waste management. The study demonstrates the synergistic application of two distinct additive manufacturing techniques (FDM and DIW) at the micron scale to create nacre‐inspired sheet, columnar, and laminated structures, allowing for manipulation of rigid and pliant material phases within KF waste. The featured architectures are found in the Mollusk Seashell, which improves toughness and strength simultaneously for high‐end mechanical applications. During impact loading, the study highlights the enhanced energy dissipation and delamination properties of foliated structures compared to nacre‐like ones. The research emphasizes that the mass loss of NS + KF comprises the lowest value compared to NC + KF, then FL + KF, and pristine + KF at 375 mJ for 210 s. Ultimately, the findings hold promise for applications in aerospace, defense, automobile, thermal management, laser ablation, and structural components due to the demand for waste utilization, accessibility, environmental responsibility, and green manufacturing practices.