Energy absorption and self-sensing performance of 3D printed CF/PEEK cellular composites

Highlights: • Multifunctional CF/PEEK lattices processed via FFF is reported. • CF/PEEK lattices exhibit 20X increase in peak stress and 5X increase in SEA. • The piezoresistive response of CF/PEEK lattices is more sensitive to cell-topology. • CF/PEEK lattices show the highest sensitivity of 5.2 under out-of-plane compression. We report the energy absorption and piezoresistive self-sensing performance of 3D printed discontinuous carbon fiber (CF)-reinforced polyetheretherketone (PEEK) cellular composites. Experiments conducted on three different 2D lattices with hexagonal, chiral and re-entrant topologies of the same relative density (33%) and CF loading (30 wt%) reveal that the CF/PEEK hexagonal lattice (HL), due its relatively brittle response, shows about 40% and 9% decrease in specific energy absorption (SEA) under in-plane and out-of-plane compression, respectively, compared with PEEK HL. While the collapse response of PEEK HL is nearly insensitive to the strain-rate over 43 ≤ $\dot{\epsilon }$ ≤ 106 s⁻¹, we observe a twenty-fold increase in peak stress and a five-fold increase in SEA under in-plane impact loading over the same range of strain-rates for the CF/PEEK HL. The CF/PEEK lattices exhibit pronounced piezoresistive response under both in-plane and out-of-plane compression with maximum sensitivity of 3.1 and 5.2, respectively, for the re-entrant lattice, offering insight into the damage-state. Higher damage sensitivity indicates faster percolation of new contacts due to folds forming between the cell walls within the lattice under compression. The energy-absorbing and strain- and damage-sensing nature of 3D printed CF/PEEK lattices demonstrated here offers insight into the design of lightweight, high-performance multifunctional lattices.