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Development of 3D Printed Biodegradable Poly-lactic Acid/Polyurethane Foams/Milled Glass Fibers of Sustainable Composites with Application on Helmet

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Abstract

Composite materials primarily contribute to engineering applications. The increase in additive manufacturing technology has many advantages in the manufacturing of composite materials. This study aims to design and fabricate a tri-material structure (TMS) composed of a 3D-printed poly-lactic acid (PLA) lattice frame infilled with polyurethane foams (PUFs) reinforced with milled glass fibers (MGFs). The mechanical behavior of the fabricated composite samples was investigated and compared to the PLA lattice of the mono-material (MMS) and PLA/PUFs of the bi-material structure (BMS). The MGFs content in TMS was varied at 1.25, 2.5, 3.75, and 5 vol%. Tensile, compression, three-point bending, and shore hardness tests were performed to determine the mechanical properties of the composite structures. The results revealed that the TMS samples exhibited the most enhanced mechanical behavior owing to their effective dispersion and load transfer ability. Finally, helmet prototypes of TMS were fabricated, tested and compared with the helmet prototypes of MMS and BMS compositions using a compression test. Findings showed that the TMS samples with 3.75 vol% showed the most enhanced tensile yield stress (9.53 ± 0.52 MPa), compression yield stress (12.21 ± 0.18 MPa), and flexural stress (14.93 ± 0.34 MPa). However, the TMS samples with 5 vol% had the most improved Shore hardness (78.86 ± 3.28). Consequently, the helmet prototype of 3.75 vol% showed the most enhanced behavior with a compressive peak force of 2752.77 ± 53.63 N due to homogeneous dispersion of incorporated MGFs in matrix.

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Data Availability Statement

The experimental datasets obtained from this research work and then the analyzed results during the current study are available from the corresponding author on reasonable request.

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  1. Bandar Aloyaydi & Fahad A. Al-Mufadi

    Present address: Department of Mechanical Engineering, College of Engineering, Qassim University, Buraidah, 51452, Saudi Arabia

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  1. Department of Mechanical Engineering, College of Engineering, Qassim University, Buraidah, 51452, Saudi Arabia

    Ammar Mustafa Al-Areqi & Subbarayan Sivasankaran

  2. Digital Manufacturing Laboratory, Department of Mechanical Engineering, College of Engineering, Qassim University, Buraidah, 51452, Saudi Arabia

    Bandar Aloyaydi, Subbarayan Sivasankaran & Fahad A. Al-Mufadi

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AMA formal analysis, validation, roles/writing-original draft. BA visualization; investigation, data curation, writing—review and editing. SS conceptualization, methodology, investigation, roles/writing-original draft. FAA-M resources, funding acquisition, project administration.

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Correspondence to Subbarayan Sivasankaran.

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Mustafa Al-Areqi, A., Aloyaydi, B., Sivasankaran, S. et al. Development of 3D Printed Biodegradable Poly-lactic Acid/Polyurethane Foams/Milled Glass Fibers of Sustainable Composites with Application on Helmet. Fibers Polym 24, 2065–2082 (2023). https://doi.org/10.1007/s12221-023-00189-6

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