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Final Year Project - Design and Optimisation of a Novel Hollow Auxetic Structure

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Project Timeline

Sep 2024 - May-2025

OVERVIEW

Individual project focusing on designing a novel hollow auxetic structure, optimising it using a finite element analysis simulations and a statistical approach and then mechanically testing 3D printed versions for mechanical testing and comparison to the simulation results. An auxetic structure is one in which is expands longitudinally as it is deformed laterally, defined by a negative Poisson's ratio.

HighlightS

  • Creation of a novel auxetic structure
  • Simulation results agree with mechanical testing
  • Hollow struts improve specific Young's Modulus by 70%
  • SLA printing proving effective for micro hollow struts

SKILLS

Parametric CAD designAnsys FEAResponse Surface MethodAdditive manufacturing - SLA & FDM printingMechanical testing - compression tests

SUPPORTING MATERIALS

Additional Details

Abstract

The demand for lightweight materials with superior mechanical properties is growing across many industries, from aerospace to biomedical. Auxetic structures, which expand laterally when stretched axially, have excellent mechanical properties, providing a unique solution to this demand. While conventional auxetic structures have been extensively studied, hollow auxetic structures have been largely unexplored, limiting the potential in lightweight engineering applications. A novel hollow auxetic unit cell has been designed, optimised, and mechanically tested to have a high negative Poisson’s ratio (NPR) and compressive strength.

A novel unit cell was created, including re-entrant and chiral auxetic mechanisms, with hollow struts, each defining a key design parameter. Design of experiment (DOE) and finite element analysis (FEA) were used to find the optimum combination of these parameters for maximum NPR. Stereolithography (SLA) printing was used to print the unit cells arrayed into a 3×3×3 structure. Compression testing revealed that the NPR of the structure was significantly less negative than the unit cell. Hollow struts, compared to solid, improved specific Young’s modulus and specific peak compressive strength by 70% and 5%, respectively. The novel design displays excellent lightweight stiffness and strength, but auxetic performance suffers as the unit cell is arrayed into a 3×3×3 structure.

Visual Representation of Project Stages


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FEA Setup

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Results


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