Influence of Lattice Infill Geometry on the Mechanical Response of Fused Filament Fabricated Zirconia Functionally Graded Structures
DOI:
https://doi.org/10.37255/jme.v21i1pp025-035Keywords:
Fused filament fabrication, zirconia, functionally graded structures, lattice infill geometry, mechanical behaviour.Abstract
Fused filament fabrication (FFF) enables the production of complex ceramic structures with tailored internal architecture. However, the influence of lattice infill geometry on the mechanical behaviour of zirconia-based functionally graded structures remains poorly characterised. This study systematically investigated the mechanical response and dimensional stability of zirconia functionally graded lattices incorporating grid, gyroid, and triangular infill patterns. Specimens were fabricated via extrusion-based FFF, followed by chemical debinding and high-temperature sintering. The mechanical performance was evaluated under compression, tension, and flexure in accordance with ASTM E9, E8, and C1161, respectively. Complementary porosity and shrinkage analyses were conducted to establish relationships between geometry and properties. Distinct topology-dependent mechanical behaviours were observed. The grid-based structures exhibited superior load-bearing capacity, sustaining maximum compressive loads of 26.0 ± 1.2 kN, followed by triangular (24.1 ± 1.5 kN) and gyroid (23.4 ± 1.8 kN) configurations. Under flexural loading, the grid lattices supported 20.0 ± 1.1 kN, compared to 15.8 ± 1.4 kN (triangular) and 11.0 ± 1.6 kN (gyroid). Tensile testing revealed similar trends: grid (15.0 ± 0.9 kN), triangle (11.5 ± 1.3 kN), and gyroid (9.7 ± 1.5 kN). Gyroid architectures demonstrated improved deformation tolerance despite lower peak loads. Shrinkage analysis confirmed geometry-dependent dimensional variations (19–22% linear shrinkage), consistent with the densification-driven behaviour typical of zirconia systems. These findings establish critical structure–property relationships for FFF-fabricated zirconia lattices, providing design guidance for lightweight ceramic components in mechanically demanding applications.
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