Optimization of 3D-printed wing spars via multi-material and graded infill additive manufacturing: An experimental study

Qayyum, Hamza and Louhichi, Borhen and Hassan, Malik and Ashfaq, Babar and Sulaiman, Muhammad and Khan, Muhammad Bilal and Alrasheedi, Nashmi H. and Hussain, Ghulam (2025) Optimization of 3D-printed wing spars via multi-material and graded infill additive manufacturing: An experimental study. EXPRESS POLYMER LETTERS, 19 (11). pp. 1173-1187. ISSN 1788-618X

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Abstract

To reduce fuel consumption and extend flight time, the aerospace industry has focused on lightweight design. Achieving this without compromising structural integrity has been challenging. However, innovative additive manufacturing offers new opportunities for practical solutions. This study presents two methods: multi-material additive manufacturing (MMAM) and variable infill density additive manufacturing (VIDAM), aimed at reducing structural weight while maintaining mechanical performance. These methods were applied to a wing spar, a test geometry based on stress distribution principles from laminated beam mechanics. The structures produced with these new approaches showed improved mechanical responses compared to those made with traditional additive manufacturing techniques. A maximum increase of 91% in load-carrying capacity and a 34.8% increase in specific energy absorption were observed. scanning electron microscopy analysis revealed that layer bonding and material diffusion greatly influenced the mechanical performance. Although the study was conducted on small-scale models, the design concepts can be adapted to large-scale industrial applications that benefit from lightweight structures, such as the aerospace and automotive.

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