Optimising 3D-printed flexible lattice structures for morphing applications by linking rheology to mechanical behaviour
Additive manufacturing, particularly extrusion-based additive manufacturing (EB-AM), has transformed the fabrication of complex structures. Thermoplastic Polyurethane (TPU), valued for its elasticity and durability, is an ideal material for flexible lattice designs. However, determining optimal rheo...
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| Format: | Article |
| Language: | English |
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Taylor & Francis Group
2025-12-01
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| Series: | Virtual and Physical Prototyping |
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| Online Access: | https://www.tandfonline.com/doi/10.1080/17452759.2025.2478514 |
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| author | Laia Farràs-Tasias Max Vermeerbergen Francisco A. Gilabert Ludwig Cardon Flavio H. Marchesini |
| author_facet | Laia Farràs-Tasias Max Vermeerbergen Francisco A. Gilabert Ludwig Cardon Flavio H. Marchesini |
| author_sort | Laia Farràs-Tasias |
| collection | DOAJ |
| description | Additive manufacturing, particularly extrusion-based additive manufacturing (EB-AM), has transformed the fabrication of complex structures. Thermoplastic Polyurethane (TPU), valued for its elasticity and durability, is an ideal material for flexible lattice designs. However, determining optimal rheological properties and printing parameters during extrusion remains a significant challenge. This study introduces the 3DFLOR framework (3D Flexible Lattice Optimisation via Rheology), a novel methodology that combines the Doehlert experimental design and Response Surface Methodology (RSM) to minimise trial and error in EB-AM. By systematically adjusting critical printing parameters, such as printing temperature and speed, the 3DFLOR framework establishes a link between the rheological and the mechanical properties. The experimental results show an enhancement of the mechanical properties tailored for the morphing application. This research not only provides a specific application optimisation but a universal methodology for optimising and linking rheology and material properties in other applications. |
| format | Article |
| id | doaj-art-ac0ebfb232a94dfeb2c41527c5c1d806 |
| institution | OA Journals |
| issn | 1745-2759 1745-2767 |
| language | English |
| publishDate | 2025-12-01 |
| publisher | Taylor & Francis Group |
| record_format | Article |
| series | Virtual and Physical Prototyping |
| spelling | doaj-art-ac0ebfb232a94dfeb2c41527c5c1d8062025-08-20T01:50:07ZengTaylor & Francis GroupVirtual and Physical Prototyping1745-27591745-27672025-12-0120110.1080/17452759.2025.2478514Optimising 3D-printed flexible lattice structures for morphing applications by linking rheology to mechanical behaviourLaia Farràs-Tasias0Max Vermeerbergen1Francisco A. Gilabert2Ludwig Cardon3Flavio H. Marchesini4Centre for Polymer and Material Technologies (CPMT), Ghent University, Ghent, BelgiumCentre for Polymer and Material Technologies (CPMT), Ghent University, Ghent, BelgiumMechanics of Materials and Structures (MMS), Ghent University, Ghent, BelgiumCentre for Polymer and Material Technologies (CPMT), Ghent University, Ghent, BelgiumCentre for Polymer and Material Technologies (CPMT), Ghent University, Ghent, BelgiumAdditive manufacturing, particularly extrusion-based additive manufacturing (EB-AM), has transformed the fabrication of complex structures. Thermoplastic Polyurethane (TPU), valued for its elasticity and durability, is an ideal material for flexible lattice designs. However, determining optimal rheological properties and printing parameters during extrusion remains a significant challenge. This study introduces the 3DFLOR framework (3D Flexible Lattice Optimisation via Rheology), a novel methodology that combines the Doehlert experimental design and Response Surface Methodology (RSM) to minimise trial and error in EB-AM. By systematically adjusting critical printing parameters, such as printing temperature and speed, the 3DFLOR framework establishes a link between the rheological and the mechanical properties. The experimental results show an enhancement of the mechanical properties tailored for the morphing application. This research not only provides a specific application optimisation but a universal methodology for optimising and linking rheology and material properties in other applications.https://www.tandfonline.com/doi/10.1080/17452759.2025.2478514Additive manufacturingrheologylattice structuresoptimisationmorphing wingDoehlert design |
| spellingShingle | Laia Farràs-Tasias Max Vermeerbergen Francisco A. Gilabert Ludwig Cardon Flavio H. Marchesini Optimising 3D-printed flexible lattice structures for morphing applications by linking rheology to mechanical behaviour Virtual and Physical Prototyping Additive manufacturing rheology lattice structures optimisation morphing wing Doehlert design |
| title | Optimising 3D-printed flexible lattice structures for morphing applications by linking rheology to mechanical behaviour |
| title_full | Optimising 3D-printed flexible lattice structures for morphing applications by linking rheology to mechanical behaviour |
| title_fullStr | Optimising 3D-printed flexible lattice structures for morphing applications by linking rheology to mechanical behaviour |
| title_full_unstemmed | Optimising 3D-printed flexible lattice structures for morphing applications by linking rheology to mechanical behaviour |
| title_short | Optimising 3D-printed flexible lattice structures for morphing applications by linking rheology to mechanical behaviour |
| title_sort | optimising 3d printed flexible lattice structures for morphing applications by linking rheology to mechanical behaviour |
| topic | Additive manufacturing rheology lattice structures optimisation morphing wing Doehlert design |
| url | https://www.tandfonline.com/doi/10.1080/17452759.2025.2478514 |
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