工業上追求快速及輕量化結構漸成趨勢，其中比金屬材料輕且具有一定強度的複合材料是發展的重點。帶有蜂窩狀的夾層結構，以優異的能量吸收能力而備受關注，廣泛用於衝擊情況下的能量吸收應用，其中，抗衝擊能力是夾層結構的關鍵指標。然而，蜂窩夾層結構常用材料為金屬，但其製造過程繁瑣、成本高且損壞時較不易修復。而熔融沉積成型(Fused Deposition Modeling, FDM) 積層列印熱塑性聚合物可以改善此問題，並且在基質聚合物上添加連續增強纖維製成夾層結構可以實現強度及複雜結構設計。基質聚合物選用微型碳纖維尼龍(Onyx)，除了能製造尺寸精度準確的零件，其成本也低於金屬材料。此外，添加連續碳纖維、克維拉後，前者具備高硬度，達到媲美鋁合金強度之零件，後者具備極佳的抗拉性能，能有效吸收衝擊，可以依據不同使用情形下提供不同選擇。
因此，本研究聚焦於利用熔融沉積成型（FDM）技術製作以Onyx材料為基底，並添加不同層數連續碳纖維與克維拉纖維的蜂窩夾層結構，探討20mm、15mm蜂窩晶格尺寸與纖維層數含量對結構衝擊性能的影響。透過落槌衝擊試驗，選用500焦耳、100焦耳能量，評估蜂窩夾層結構在不同衝擊能量下的反應，並比較連續纖維種類、層數、晶格大小的性能差異。最後用有限元素分析建立靜態分析，觀察結構以及材料種類在受到力時的等效應力分布及變形量。
實驗結果顯示，蜂窩晶格尺寸對結構衝擊力學行為影響顯著，20mm晶格呈現較高峰值力及明顯應力集中，而15mm晶格則展現較為均勻的力分散與能量吸收能力。連續纖維層數增加確實提升峰值力，但在纖維層數達一定數量後，碳纖維與克維拉的性能差異趨於平緩。此外，連續碳纖維樣品初期反應力較克維拉強，但克維拉因其韌性在衝擊後段表現出更佳的能量吸收與延展性能。

In the industry, there is an increasing trend toward the pursuit of rapid and lightweight structural solutions, with composite materials—lighter than metals yet possessing a certain level of strength—becoming a key focus of development. Honeycomb sandwich structures have garnered considerable attention due to their exceptional energy absorption capabilities and are widely used in applications that require impact energy absorption. Among these, impact resistance is a critical performance indicator for sandwich structures. However, honeycomb sandwich structures are commonly made of metals, which involve complex manufacturing processes, high costs, and increased difficulty in repair when damaged. Fused Deposition Modeling (FDM) additive manufacturing of thermoplastic polymers offers a potential solution to these issues. Furthermore, incorporating continuous reinforcement fibers into the polymer matrix enables the production of sandwich structures with both high strength and complex geometries. In this study, Onyx was selected as the matrix polymer, as it not only allows for the fabrication of dimensionally accurate parts but also offers a lower cost compared to metal materials. The addition of continuous carbon fiber and Kevlar provides distinct advantages: the former delivers high rigidity and strength comparable to that of aluminum alloys, while the latter offers excellent tensile performance and effective impact absorption, providing material options tailored to different application requirements.
This study focuses on using FDM technology to fabricate honeycomb sandwich structures with Onyx as the matrix material, incorporating varying numbers of Continuous Carbon Fiber and Kevlar layers. The effects of honeycomb lattice sizes (20 mm and 15 mm) and fiber layer counts on the impact performance of the structure were investigated. Drop-weight impact tests were conducted at energy levels of 500 J and 100 J to evaluate the response of the honeycomb sandwich structures under different impact energies and to compare performance differences among fiber types, layer counts, and lattice sizes. Finally, a static analysis was conducted using finite element analysis to observe the equivalent stress distribution and deformation of the structure and material type under applied loading.
The experimental results indicate that the size of the honeycomb lattice has a significant impact on its structural and mechanical behavior. The 20 mm lattice exhibited a higher peak force and more pronounced stress concentration, while the 15 mm lattice demonstrated a more uniform load distribution and improved energy absorption capability. Increasing the number of continuous fiber layers enhanced the peak force; however, once the fiber layer count reached a certain level, the performance differences between Continuous Carbon Fiber and Kevlar began to level off. Additionally, the Continuous Carbon Fiber sample showed stronger initial reaction forces compared to Kevlar; however, due to its toughness, Kevlar demonstrated superior energy absorption and ductility in the later stages of the impact.

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