3D printed functionally graded foams response under transverse load

The applications of 3D printing are rapidly increasing in aerospace and naval applications. Nonetheless, 3D printing (3DP) of graded foams exhibiting property variation along the thickness direction is yet to be explored. In the current work, the different volume fractions of hollow glass micro balloon (GMB) reinforced high-density polyethylene (HDPE) composite based graded foams are 3D printed using the fused deposition modelling (FDM) technique. The bonding between successive layers and porosity distribution of these graded configurations are studied using micro-CT scan. Further, the 3D Printed functionally graded foams (FGFs) are tested for flexural response, and results are compared with numerical values. The micro-CT results showed delamination absence between the layers. In neat HDPE layers, porosity is not evident, while minor porosity creeps in the layers having the highest GMB content. Experimental results of the flexural test showed that the graded sandwiches exhibited better strength than the graded core alone. Compared to neat HDPE, the modulus of FGF-2 (H20–H40–H60) increased by 33.83%, implying better mechanical stiffness. Among all the FGFs, FGF-2 exhibited a better specific modulus. A comparative study of experimental and numerical results showed a slight deviation due to neglecting the induced porosity.