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Optimising 3D-printed flexible lattice structures for morphing applications by linking rheology to mechanical behaviour

Laia Farràs Tasias (UGent) , Max Vermeerbergen, Francisco A. Gilabert (UGent) , Ludwig Cardon (UGent) and Flavio H. Marchesini (UGent)
(2025) VIRTUAL AND PHYSICAL PROTOTYPING. 20(1).
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Abstract
Additive manufacturing, particularly extrusion-based additive manufacturing (EB-AM), has transformed the fabrication of complex structures. Thermoplastic Polyurethane (TPU), valued for its elasticity and durability, is an ideal material for flexible lattice designs. However, determining optimal rheological properties and printing parameters during extrusion remains a significant challenge. This study introduces the 3DFLOR framework (3D Flexible Lattice Optimisation via Rheology), a novel methodology that combines the Doehlert experimental design and Response Surface Methodology (RSM) to minimise trial and error in EB-AM. By systematically adjusting critical printing parameters, such as printing temperature and speed, the 3DFLOR framework establishes a link between the rheological and the mechanical properties. The experimental results show an enhancement of the mechanical properties tailored for the morphing application. This research not only provides a specific application optimisation but a universal methodology for optimising and linking rheology and material properties in other applications.
Keywords
Additive manufacturing, rheology, lattice structures, optimisation, morphing wing, Doehlert design, MATERIAL EXTRUSION, OPTIMIZATION, DESIGN, PARTS, SIMULATIONS, METHODOLOGY, FABRICATION, ELASTOMERS, PARAMETERS, SCHWARZ

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MLA
Farràs Tasias, Laia, et al. “Optimising 3D-Printed Flexible Lattice Structures for Morphing Applications by Linking Rheology to Mechanical Behaviour.” VIRTUAL AND PHYSICAL PROTOTYPING, vol. 20, no. 1, 2025, doi:10.1080/17452759.2025.2478514.
APA
Farràs Tasias, L., Vermeerbergen, M., Gilabert, F. A., Cardon, L., & Marchesini, F. H. (2025). Optimising 3D-printed flexible lattice structures for morphing applications by linking rheology to mechanical behaviour. VIRTUAL AND PHYSICAL PROTOTYPING, 20(1). https://doi.org/10.1080/17452759.2025.2478514
Chicago author-date
Farràs Tasias, Laia, Max Vermeerbergen, Francisco A. Gilabert, Ludwig Cardon, and Flavio H. Marchesini. 2025. “Optimising 3D-Printed Flexible Lattice Structures for Morphing Applications by Linking Rheology to Mechanical Behaviour.” VIRTUAL AND PHYSICAL PROTOTYPING 20 (1). https://doi.org/10.1080/17452759.2025.2478514.
Chicago author-date (all authors)
Farràs Tasias, Laia, Max Vermeerbergen, Francisco A. Gilabert, Ludwig Cardon, and Flavio H. Marchesini. 2025. “Optimising 3D-Printed Flexible Lattice Structures for Morphing Applications by Linking Rheology to Mechanical Behaviour.” VIRTUAL AND PHYSICAL PROTOTYPING 20 (1). doi:10.1080/17452759.2025.2478514.
Vancouver
1.
Farràs Tasias L, Vermeerbergen M, Gilabert FA, Cardon L, Marchesini FH. Optimising 3D-printed flexible lattice structures for morphing applications by linking rheology to mechanical behaviour. VIRTUAL AND PHYSICAL PROTOTYPING. 2025;20(1).
IEEE
[1]
L. Farràs Tasias, M. Vermeerbergen, F. A. Gilabert, L. Cardon, and F. H. Marchesini, “Optimising 3D-printed flexible lattice structures for morphing applications by linking rheology to mechanical behaviour,” VIRTUAL AND PHYSICAL PROTOTYPING, vol. 20, no. 1, 2025.
@article{01JQE5P6EQJT89XAQNHHY7W2BY,
  abstract     = {{Additive manufacturing, particularly extrusion-based additive manufacturing (EB-AM), has transformed the fabrication of complex structures. Thermoplastic Polyurethane (TPU), valued for its elasticity and durability, is an ideal material for flexible lattice designs. However, determining optimal rheological properties and printing parameters during extrusion remains a significant challenge. This study introduces the 3DFLOR framework (3D Flexible Lattice Optimisation via Rheology), a novel methodology that combines the Doehlert experimental design and Response Surface Methodology (RSM) to minimise trial and error in EB-AM. By systematically adjusting critical printing parameters, such as printing temperature and speed, the 3DFLOR framework establishes a link between the rheological and the mechanical properties. The experimental results show an enhancement of the mechanical properties tailored for the morphing application. This research not only provides a specific application optimisation but a universal methodology for optimising and linking rheology and material properties in other applications.}},
  articleno    = {{e2478514}},
  author       = {{Farràs Tasias, Laia and Vermeerbergen, Max and Gilabert, Francisco A. and Cardon, Ludwig and Marchesini, Flavio H.}},
  issn         = {{1745-2759}},
  journal      = {{VIRTUAL AND PHYSICAL PROTOTYPING}},
  keywords     = {{Additive manufacturing,rheology,lattice structures,optimisation,morphing wing,Doehlert design,MATERIAL EXTRUSION,OPTIMIZATION,DESIGN,PARTS,SIMULATIONS,METHODOLOGY,FABRICATION,ELASTOMERS,PARAMETERS,SCHWARZ}},
  language     = {{eng}},
  number       = {{1}},
  pages        = {{19}},
  title        = {{Optimising 3D-printed flexible lattice structures for morphing applications by linking rheology to mechanical behaviour}},
  url          = {{http://doi.org/10.1080/17452759.2025.2478514}},
  volume       = {{20}},
  year         = {{2025}},
}
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