Glasgow Engineers Develop Ultra‑Light, High‑Impact 3D‑Printed Composite for Automotive and Aerospace

University of Glasgow engineers have pioneered a 3D‑printed composite that blends polyolefin resins with multi‑wall carbon nanotubes, delivering a material that is both lighter and tougher than conventional aluminum. In their recent paper, "Impact Behaviour of Nanoengineed, 3D‑Printed Plate‑Lattices," published in *Materials & Design*, the team details a novel plate‑lattice metamaterial exhibiting exceptional impact resistance.

Metamaterials are engineered cellular solids engineered to exhibit properties absent in nature. Plate‑lattices, a subset of these, are cubic frameworks of intersecting plates that achieve remarkable stiffness and strength while maintaining high porosity, which in turn keeps them lightweight.

The team explored whether plate‑lattice geometries fabricated from their novel plastic‑nanotube composite could surpass existing materials in stiffness, strength, and toughness. Using the composite filament as 3D‑printing feedstock, they printed multiple lattice configurations and subjected each to drop‑impact tests—releasing a 16.7‑kg weight from various heights—to assess shock resilience.

Initially, the researchers fabricated three canonical plate‑lattice variants: a basic cubic unit comprising three intersecting plates; a more intricate cube featuring additional plate intersections; and a multifaceted design. Each variant was produced in two material series—polypropylene (PP) and polyethylene (PE).

Subsequently, they evaluated three hybrid plate‑lattices that merged attributes from the initial designs: a simple‑cube/complex‑cube hybrid, a simple‑cube/multifacet hybrid, and a composite hybrid that integrated all three elements. These hybrids were also fabricated from PP and PE.

The all‑in‑one hybrid demonstrated the highest impact absorption, particularly the PP variant. When evaluated by specific energy absorption—a metric of energy absorbed per unit mass—the PP hybrid sustained 19.9 J g⁻¹, surpassing comparable aluminum‑based microarchitected metamaterials.

Dr Shanmugam Kumar, Lead of the Composites and Additive Manufacturing group at the University of Glasgow’s James Watt School of Engineering, spearheaded the study. The project also enlisted mechanical and chemical engineers from Khalifa University in Abu Dhabi and Texas A&M University at College Station, USA.

Kumar explained, "This research sits at the crossroads of mechanics and materials science. By balancing our nano‑engineered filament feedstock with sophisticated hybrid lattice designs, we have achieved unprecedented stiffness, strength, and energy‑absorption performance. Advances in 3D printing now enable cost‑effective fabrication of such intricate, highly porous geometries, bringing industrial‑scale production within reach."

Kumar highlighted automotive manufacturing as a key use case, noting that the relentless pursuit of lighter vehicle bodies demands materials that do not compromise crash safety. "While aluminum is widely used, our plate‑lattice delivers superior impact resistance, making it a promising candidate for future automotive structures. Additionally, the recyclability of the plastics involved aligns with the global shift toward net‑zero and circular economies," he added.