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This research was funded by IDUB-IMech Warsaw University of Technology, entitled
“Badania hybrydowych elementów nadwozi pojazdów kołowych w zakresie pozyskiwania energii i
monitoringu konstrukcji”.
This article presents the concept, research, and modeling of a sandwich composite made
from ULTEM 9085 and polycarbonate (PC). ULTEM 9085 is relatively expensive compared to polycar-
bonate, and the composite structure made of these two materials allows for maintaining the physical
properties of ULTEM while reducing the overall costs. The composite consisted of outer layers
made of ULTEM 9085 and a core made of polycarbonate. Each layer was 3D-printed using the fused
filament fabrication (FFF) technology, which enables nearly unlimited design flexibility. The geometry
of the test specimens corresponds to the ISO 527-4 standard. Tensile and three-point bending tests
were conducted. The structure was modeled in a simplified manner using averaged stiffness values,
and with the classical laminate theory (CLT). The models were calibrated through tensile and bending
tests on ULTEM and polycarbonate prints. The simulation results were compared with experimental
data, demonstrating good accuracy. The 3D-printed ULTEM-PC-ULTEM composite exhibits favorable
mechanical properties, making it a promising material for cost-effective engineering applications.