Effect of density and unit cell size grading on the stiffness and energy absorption of short fibre-reinforced functionally graded lattice structures

Architectured structures, particularly functionally graded lattices, are receiving much attention in both industry and academia as they facilitate the customization of the structural response and harness the potential for multifunctional applications. This work experimentally investigates how the severity of density and unit cell size grading as well as the building direction affects the stiffness, energy absorption and structural response of additively manufactured (AM) short fibre-reinforced lattices with same relative density. Specimens composed of tessellated body-centred cubic (BCC), Schwarz-P (SP) and Gyroid (GY) unit cells were tested under compression. Compared to the uniform lattices of equal density, it was found, that modest density grading has a positive and no effect on the total compressive stiffness of SP and BCC lattices, respectively. More severe grading gradually reduces the total stiffness, with the modulus of the SP lattices never dropping below that of the uniform counterparts. Unit cell size grading had no significant influence on the stiffness and revealed an elastomer-like performance as opposed to the density graded lattices of the same relative density, suggesting a foam-like behaviour. Density grading of bending-dominated unit cell lattices showcased better energy absorption capability for small displacements, whereas grading of the stretching-dominated counterparts is advantageous for large displacements when compared to the ungraded lattice. The severity of unit cell size graded lattices does not affect the energy absorption capability. Finally, a power-law approach was used to semi-empirically derive a formula that predicts the cumulative energy absorption as a function of the density gradient and relative density. Overall, these findings will provide engineers with valuable knowledge that will ease the design choices for lightweight multi-functional AM-parts.