Manufacturing Optimization and Mechanical Performance Evaluation of Graphene/Glass Fiber Reinforced Hybrid Composite Lattice Structures via SLA

This study investigates the mechanical performance and process optimization of hybrid composite lattice structures fabricated via Stereolithography (SLA). To enhance the structural integrity of additively manufactured components, an ABS-like resin was reinforced with glass fiber and varying concentrations of graphene (0.05, 0.1, and 0.2 wt.%). Three different lattice topologies (Truncated, Kelvin, and Fluorite) were designed and subjected to quasi-static compression tests. The Taguchi method (L9 orthogonal array) and ANOVA were employed to identify the optimal manufacturing parameters. Results indicated that the Truncated lattice reinforced with 0.1 wt.% graphene exhibited superior mechanical properties, achieving a peak stress of 5.085 MPa and an energy absorption (EA) of 49.93 kJ/m3. Microstructural analysis via SEM revealed that while 0.1 wt.% graphene provided effective reinforcement, higher concentrations (0.2 wt.%) caused agglomeration, leading to stress concentrations and premature brittle fractures. Statistical analysis confirmed that graphene content is the most significant factor affecting energy absorption (58.2% contribution). This work establishes a clear structure–property relationship for SLA-fabricated hybrid composites, offering an optimized route for developing lightweight, high-strength structures. Fabrication of hybrid composite lattice structures via SLA using graphene and glass fiber. Microstructural analysis revealed particle agglomeration at 0.2 wt.% graphene reinforcement. Truncated lattice with 0.1 wt.% graphene exhibited the highest compressive strength of 5.085 MPa. Maximum energy absorption of 49.93 kJ/m³ was achieved in the optimized truncated lattice design with 0.1 wt.%. ANOVA results identified graphene content as the dominant factor (58.2%) on energy absorption.