The present work aim is to fully apply the potential of FDM (Fused Deposition Modelling) technology with economic printing machine, in order to create performant ABS cores, to be subsequently used as shaped moulds for sandwich plate assembly with GFRP skins, representing simple prototypes to validate production concept and its structural behaviour. The further task of this study is to empirically optimize the geometry of the core as function of required thickness and technological building parameters, in order to achieve light and mechanically performing structures with extremely reduced costs. After compression experimental tests on core cell geometries, fatigue tests under bending are also executed on reinforced GFRP plates in order to validate best compromise between ABS core design and GFRP laminated skin properties and stiffness requirement, highlighting influence of ABS wire performances as deposited in the form of beam-based lattice geometry. In addition, the authors employ the digital image correlation technique to perform the strain and displacement field of lattice structures and sandwich interfaces.
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