Development of lattice core ultra-light sandwich composite materials for vehicles by using 3D composite printing

The additive manufacturing method is a production method in which products are obtained by the accumulation of three-dimensional models in layers. Today, interest in composite materials has increased in order to reduce the total weight and to obtain products with sufficient strength. Among the structures developed in this direction, sandwich structures have special interest in many areas. Due to their low weight, high bending strength, energy absorption, they are used in different areas. In addition, lattice core sandwich structures are produced to produce ultra-light materials. Additive manufacturing of composite materials attracts the attention of industrial applications and research. In this study, a 3D printer with an improved extruder was used to produce continuous carbon fiber reinforced polypropylene matrix composites. The lattice core of sandwich structures was produced with this printer. 0/90/0 directional plates and core structures are combined with hot silicon. Compression, three-point bending, quasi-static and three-point bending impact tests were applied to the produced sandwich structures. In addition, a fiber separation system was designed and manufactured to improve the production of continuous carbon fiber reinforced thermoplastic polymer filaments. In this way, tapes were produced for use in the developed 3D printer. In addition, a laser assisted additive manufacturing system has been developed for the production of composite structures. This system was integrated into the developed large-size 3D printer and a new system was introduced.