Material extrusion additive manufacturing is a widely used 3D-printing process. Combining material extrusion with composites creates strong, lightweight, and functional parts with unique properties.This paper presents lightweight sandwich structures made from carbon-fibre-reinforced polymer skins and a glass-fibre-reinforced polymer core using 3D printing. The structures’ mechanical performance was assessed through tests, including tensile, and compression strength. In this work, the 3D-printed sheet using FDM (fused deposition modelling), optimized with the optimal infill pattern, was employed as the core material. This core was then sandwiched between layers of carbon fibre sheets placed at the bottom. Additionally, a glass fibre mat was inserted on the outermost layers of the sandwich construction. A comparative study was conducted to validate experimental results and understand the mechanical behaviour of the 3D-printed structures. The aim was to understand how the type and strategy of infill design impact the material’s mechanical properties, helping optimize the performance of composite samples. The composite, consisting of a glass fibre top layer, an FDM carbon filament sheet core, and a carbon fibre bottom layer with resin, has superior performance compared to other configurations. It achieves a maximum stress of about 68 MPa and a strain of 18%.
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Raghava et al. (2024) studied this question.
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