Mechanical Characterization and Finite Element Analysis of Hierarchical Sandwich Structures with PLA 3D-Printed Core and Composite Maize Starch Biodegradable Skins

Abstract

The objective of this research is the fabrication of biodegradable starch-based sandwich materials. The investigated sandwich structures consist of maize starch-based films as skins and biodegradable 3D-printed polylactic filaments (PLA) as the core. To investigate the tensile properties of the skins, conventional and nanocomposite films were prepared by a solution mixing procedure with maize starch and glycerol as the plasticizer, and they were reinforced with sodium montmorillonite clay, cellulose fibers and fiberglass fabric, with different combinations. Test results indicated a significant improvement in the mechanical and morphological properties of composite films prepared with sodium montmorillonite clay in addition with cellulose fibers and fiberglass fabric, with 20 wt% of glycerol. The morphology of the skins was also examined by scanning electron microscopy (SEM). Three orders of hierarchical honeycombs were designed for the 3D-printed core. To investigate how the skin material and the design of the core affect the mechanical properties of the starch-based sandwich, specimens were tested under a three-point bending regime. The test results have shown that the flexural strength of the biodegradable sandwich structure increased with the use of a second order hierarchy core and starch-based skins improved the strength and stiffness of the neat PLA-based honeycomb core. The bending behavior of the hierarchical honeycombs was also assessed with finite element analysis (FEA) in combination with experimental findings. Flexural properties demonstrated that the use of starch-based films and a PLA honeycomb core is a suitable solution for biodegradable sandwich structures.