Field-driven design of functionally graded TPMS-based 3D printed sandwich structures: Modeling, printing and testing
Gabriele Marabello, Guido Di Bella
Abstract. Sandwich structures with Triply Periodic Minimal Surface (TPMS) cores represent an innovative solution for lightweight applications requiring optimized mechanical properties and high strength-to-weight ratios. In this work, functionally graded TPMS-based sandwich structures were designed using a Field-Driven Design approach, allowing precise spatial variation of core thickness. Samples were fabricated via Material Extrusion (MEX), ensuring accurate reproduction of the designed gradient. Mechanical characterization through ASTM D790 three-point bending tests revealed that functional gradients significantly improve mechanical efficiency, particularly at higher fill percentages (≥30%), with strength increases up to 55% compared to uniform-thickness structures. However, at lower fill percentages (~20%), this advantage diminishes, highlighting a critical threshold for effective gradient application. The clear identification of this threshold constitutes a novel contribution, providing practical guidelines for the design and optimization of advanced TPMS-based sandwich structures.
Keywords
Material Extrusion (MEX), Design Optimization, Composites
Published online 9/10/2025, 9 pages
Copyright © 2025 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA
Citation: Gabriele Marabello, Guido Di Bella, Field-driven design of functionally graded TPMS-based 3D printed sandwich structures: Modeling, printing and testing, Materials Research Proceedings, Vol. 57, pp 556-564, 2025
DOI: https://doi.org/10.21741/9781644903735-65
The article was published as article 65 of the book Italian Manufacturing Association Conference
Content from this work may be used under the terms of the Creative Commons Attribution 3.0 license. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.
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