Crushing behavior optimization of octagonal lattice‐structured thin‐walled 3D printed carbon fiber reinforced PETG (CF/PETG) composite tubes under axial loading

Thin‐walled structures with good energy absorption capability can significantly use as energy absorbers in passive vehicle safety systems. The present study deals with designing and developing thin‐walled carbon fiber (CF) reinforced PETG (polyethylene terephthalate glycol) composite tubes with octagonal corrugated lattice structures on the lateral surfaces. The FFF (fused filament fabrication) factors such as layer height, nozzle temperature, printing speed, line width, and infill density were optimized. The experiment outcomes such as compressive strength and dimensional length error, are measured for the respective octagonal corrugated lattice structure incorporated in 3D printed CF/PETG composite tubes. The results proclaimed that, the optimum factors for improved compressive strength in the octagonal corrugated lattice‐structured CF/PETG composite will be 0.1 mm layer height, 220°C nozzle temperature, 20 mm/sec printing speed, 0.1 mm line width and 100% infill density. Furthermore, the R‐square value for the compressive strength and dimensional length error is within an acceptable limit of 91.25% and 93.31%. So, the developed mathematical models are in good form for practical acceptance. The optimized condition3D printed samples exhibit better compressive strength and lower dimensional length deviation, which is essential for considering it in the safety protection application in automotive components. Highlights • 3D printed octagonal shaped lattice structured PETG/CF composite tube. • Process parameters were optimized in terms of compressive strength. • Layer height has contributed a major impact on the compressive strength response. Schematic layout of 3D‐printed carbon fiber reinforced PETG composite and its optimal compressive results