Experimental investigation and multi-response optimization of FFF-printed PETG sandwich structure properties for battery casings

Suteja, T. J.; Hadiyat, M. A.; Pratiknyo, Y. B.

doi:10.22061/jcarme.2026.113094.2832

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	Experimental investigation and multi-response optimization of FFF-printed PETG sandwich structure properties for battery casings
Journal of Computational & Applied Research in Mechanical Engineering (JCARME)
مقالات آماده انتشار، پذیرفته شده، انتشار آنلاین از تاریخ 22 شهریور 1405 اصل مقاله (995.19 K)
نوع مقاله: Research Paper
شناسه دیجیتال (DOI): 10.22061/jcarme.2026.113094.2832
نویسندگان
T. J. Suteja^* ¹؛ M. A. Hadiyat²؛ Y. B. Pratiknyo¹
¹Department of Mechanical Engineering, Faculty of Engineering, University of Surabaya, Surabaya, Indonesia
²Department of Industrial Engineering, Faculty of Engineering, University of Surabaya, Surabaya, Indonesia
تاریخ دریافت: 01 خرداد 1405، تاریخ بازنگری: 18 شهریور 1405، تاریخ پذیرش: 22 شهریور 1405
چکیده
The increasing demand for strong, lightweight, and thermally efficient battery casings in electric vehicles has accelerated the exploration of additive-manufactured sandwich structures. This research examined how shell thickness and infill density jointly affect the impact strength, mass, and thermal conductivity of sandwich-structured Polyethylene Terephthalate Glycol specimens produced via fused filament fabrication. A factorial experimental design was used, varying shell thickness (400, 800, and 1200 µm) and infill density (20, 50, and 80%). Two-way Analysis of Variance was applied to analyze the data statistically. The results revealed that shell thickness significantly influenced all three responses (p ≤ 0.05), increasing impact strength by approximately 53% and thermal conductivity by approximately 31% as shell thickness increased from 400 to 1200 µm, at the cost of a nearly 35% increase in mass. Infill density strongly affected mass and thermal conductivity, increasing thermal conductivity by approximately 127% and mass by approximately 63% from 20% to 80% infill, but had a negligible effect on impact strength (p > 0.05). Then, fractography analysis revealed distinct failure modes and validated the meso-structure's role in mechanical and thermal performance. Applying desirability function-based multi-response optimization, the best configuration was determined to be a 1200 µm shell thickness paired with 50% infill density, predicting an impact strength of 28.57 kJ/m², thermal conductivity of 3.09 W/m·K, and mass of 3.34 g. This study provides a strategy for producing lightweight, impact-resistant, and thermally efficient additive-manufactured sandwich structures for potential electric vehicle battery casing applications.
کلیدواژه‌ها
Additive manufacturing؛ Shell thickness؛ Infill density؛ Thermo-mechanical؛ Fractography

مراجع
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Experimental investigation and multi-response optimization of FFF-printed PETG sandwich structure properties for battery casings