Study on the bending and dimensional behavior of honeycomb latticed ONYX composite material

Engineering, architecture, and transportation all use honeycomb structures in various ways. Latticing, made possible by additive manufacturing (AM), may significantly speed up the creation of adaptable structures. The current study focuses on assessing the impact of various three-dimensional (3D)-printing features on the flexural behavior and dimensional studies of the honeycomb latticed micro-carbon fiber reinforced nylon (ONYX) material. The experiment is performed by varying the levels of 3D-printing features like layer thickness (LT), infill geometry (IG), build direction (BD), shell count (SC), and infill percentage (IP) to measure the bending strength, length deviation, and lattice surface morphology variation. The experimental results show that, the peak flexural strength of 79.84 MPa is attained with specimen fabricated at 0.1 mm LT, 50% IP, 0° BD, rectilinear IG, and SC of 3. And moreover, these respective 3D-printing feature levels resulted in an improved surface morphology on the latticed specimens. The length deviation results clearly depict that specimen fabricated at lower LT of 0.1 mm, higher SC of 3, rectilinear IG, 0° BD, and higher IP of 50% consequences in accurate profile with a lower length deviation of 0.117 mm. The fractography results clearly implies that the 0° oriented latticed ONYX composite results in a progressive fracture and results in higher bending stress. On the other hand, the 45° and 90° oriented latticed ONYX materials undergo tilted fracture and perpendicular mode of fracture, respectively. From that it is concluded that, the triangular-shaped honeycomb latticed ONYX materials are suitable for the development of brackets for the portable cameras, medical, and dental appliances like prosthetics for lightweight splints in postsurgery.