Interfacial enhancements between a three-dimensionally printed Honeycomb-Truss core and woven carbon fiber/polyamide-6 facesheets in sandwich-structured composites

A novel sandwich-structured composite comprising a three-dimensionally (3D) printed core and a woven carbon fiber/polyamide-6 facesheet was fabricated and characterized. By using selective laser sintering, which is a 3D printing technology, a structurally reinforced honeycomb-truss hybrid core was produced, which had superior compressive stiffness in various directions compared with conventional honeycomb cores. The interface between the core and the facesheet was enhanced by laser power control during the sintering as well as plasma surface treatment. The sandwich composite was produced by the reactive thermoplastic resin transfer molding (T-RTM) technique using anionic polymerization of e-caprolactam, which has an ultra-low viscosity in the molten state. This in-situ polymerization not only enabled manufacturing process simplification by combining fabrication and bonding processes of the facesheet, but also provided excellent resin impregnation into the fiber fabrics and core surface. Therefore, the 3D printing technology, interfacial strengthening techniques, and T-RTM process induced synergistic effects on mechanical properties of the sandwich composite by forming structural reinforcement and strong mechanical and chemical interactions. The edgewise compressive properties of the hybrid core were significantly better than those of a normal honeycomb core. In addition, the interlaminar fracture toughness, impact energy absorption, and penetration limit of the sandwich composite consisting of the structurally and interfacially strengthened hybrid core increased by 76, 77, and 125%, respectively, compared to those of a nonreinforced sandwich composite.