Potentiality of Complex Shape Structures in FRP/Titanium-Lattice
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Composite-metal hybrid structures are increasingly utilized in structural applications, particularly in flat sandwich configurations. However, the growing demand for lightweight, high-performance components with complex, non-axisymmetric three-dimensional geometries drives the need for advanced manufacturing solutions. Among these, the integration of metallic lattice cores with composite faces offers a promising path to enhance structural efficiency. Metal octet-truss lattice structures produced via additive manufacturing allow for excellent stiffness and strength-to-weight ratios [1]. When combined with fiber-reinforced polymer (FRP) skins, they enable more uniform load distribution and improved mechanical performance [2]. This study investigates the feasibility of fabricating hybrid free-form components featuring an octet-truss metal core manufactured using the Electron Beam Powder Bed Fusion (EB-PBF) process and wrapped with FRP skins. Particular attention is given to the manufacturability of geometrically complex lattice structures, aiming to meet the demands of non-standard structural applications. In parallel, a numerical model is developed to predict the mechanical behavior of such kind of hybrid components, taking into account the complex geometry and multi-material interactions. The model is validated by means of experimental tests to ensure accuracy and reliability. The research aims to evaluate both the technological potential and the mechanical performance of these hybrid structures, with prospective applications in aerospace, automotive, and other sectors where weight saving, design flexibility, and structural integrity are mandatory.