Mechanical Characteristics of Multi-Level 3D-Printed Silicone Foams

Three-dimensional-printed silicone rubber foams, with their designable and highly ordered pore structures, have shown exceptional potential for engineering applications, particularly in areas requiring energy absorption and cushioning. However, optimizing the mechanical properties of these foams through structural design remains a significant challenge. This study addresses this challenge by formulating the research question: How do different 3D-printed topologies and printing parameters affect the mechanical properties of silicone rubber foams, and how can we design a novel topological structure? To answer this, we explored the mechanical behavior of two common structures–simple cubic (SC) and face-centered tetragonal (FCT)–by varying printing parameters such as filament spacing, filament diameter, and layer height. Furthermore, we proposed a novel two-level 3D-printed structure, combining SC and FCT configurations to enhance performance. The results demonstrated that the two-level SC-SC structure exhibited a specific energy absorption of 8.2 to 21.0 times greater than the SC structure and 2.3 to 7.2 times greater than the FCT structure. In conclusion, this study provides new insights into the design of 3D-printed silicone rubber foams, offering a promising approach to developing advanced cushioning materials with superior energy absorption capabilities.