Effects of undulating printing paths on axial compressive behaviors of 3D-printed continuous fiber-reinforced multi-cell thin-walled structure

Thin-walled structures are widely used in passive safety systems of the vehicles because of their excellent lightweight and stable progressive deformation behavior. Recently, continuous fiber 3D printing technique has been successfully applied in the manufacturing of thin-walled structures, providing a promising path to meet increasing requirements for energy absorbers as vehicle speed increases. This paper proposed a range of novel undulating printing paths to fabricate two kinds of continuous Kevlar fiber reinforced multi-cell thin-walled structures (CFMSs) with different cross-section shapes, named MT1 and MT2, respectively. For each type of CFMS, three different printing paths (moving back and forth between two layers) were designed to manufacture CFMS with the wall thickness comprised of only a single deposited line. The axial compressive tests were conducted to investigate the compressive response of CFMSs. It was found that undulating printing paths affect both the mechanical behavior and collapse mode of CFMSs. During the compression process, MT1 and MT2 printed with path 3 showed progressively folding deformation modes (differed from the progressive crushing mode of composite laminated thin-walled structures). Thus, compared to MT2 printed with path 1 and path 2, which exhibit global buckling, MT1 and MT2 printed with path 3 exhibited more stable energy absorption performance. Besides, although the local failure mode in different CFMSs caused by the same path was similar, the same printing path had different influences on the axial compressive properties of different CFMSs.