Design, Fabrication, and Testing of Impact-Resistant Metastructures

Impact-resistant structures are essential in many everyday and critical applications, from shoes and helmets to automotive, aerospace, and structural systems. These structures must be able to absorb and dissipate energy in order to protect people and equipment during impact events. This research focuses on the design, fabrication, and testing of an impact-resistant structure with an emphasis on four key metrics: lightweight, impact resistance, low cost, and fast fabrication. The project will begin with the design and fabrication of lattice-based metastructures using additive manufacturing methods. Two different printing techniques will be used: fused deposition modeling (FDM) and resin vat photopolymerization (VPP). To validate the performance of these fabricated structures, a series of mechanical tests will be conducted. First, quasi-static compression testing will be performed using a Universal Testing Machine (UTM) to measure stiffness, peak compressive strength, and overall energy absorption. Following this stage, a custom drop tower will be constructed to perform controlled impact testing. The tower will incorporate high-speed cameras, accelerometers, and piezoelectric force sensors to capture deformation behavior and measure the response of the structures during impact. The collected data will be used to generate force-displacement relationships and evaluate the energy absorption and failure behavior of each structure. These results will help inform the design of improved lightweight metastructures capable of maximizing impact resistance while remaining cost-effective and practical to manufacture.
<p>Additional Co-Authors: Alex Medeiros