Title: Electroplating Additively Manufactured Honeycomb Structures to Increase Energy Absorption Under Crush and Impact

Authors: Colleen Murray, Sean Wise and Norman M. Wereley

DOI: 10.33599/nasampe/c.24.0330

Abstract: Honeycomb (HC) has been used in energy absorption applications due to its high stiffness and low density. Literature supports the use of metallic honeycomb, in particular, for energy absorption applications, however, these metallic structures can be challenging to manufacture. Engineers have turned to using additive manufacturing (AM) to make these metallic honeycomb due to the ease of manufacturing complex features that improve energy absorption that cannot be done using conventional manufacturing. Some commonly used AM methods include powder bed fusion (PBF) and direct energy deposition (DED). These processes have deficits including a required inert environment, porosity, residual stresses, and poor surface finish. These concerns can be alleviated through the use of polymer additive manufacturing, however, these polymeric parts are unable to achieve the stiffness of metallic honeycomb. In this study, a low cost 3D polymer printing method, stereolithography (SLA), is combined with a conventional electroplating process to create a metallic-plastic composite honeycomb with comparable strength to metal honeycomb. SLA parts have a smooth surface, so that electroplating can be applied uniformly. The energy absorption characteristics of electroplated additively manufactured SLA honeycomb is studied to determine how these energy absorbing materials can be manufactured at reduced cost. Our study confirms that electroplating SLA honeycomb increases both the crush strain range and the mean crush stress of these samples, resulting in stronger parts with increased energy absorption. The study also examines how buckling initiators, or diamond shaped holes located at 50, 75, and 100% of the height of the hexagonal cell vertices, can influence energy absorption performance. Electroplated SLA honeycombs present a substantial increase in energy absorption performance over SLA alone.

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Conference: CAMX 2024 | San Diego CA

Publication Date: 2024/9/9

SKU: TP24-0000000330

Pages: 12

Price: $24.00