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

Suteja, The Jaya and Hadiyat, Mochammad Arbi and Pratiknyo, Yuwono Budi (2026) Experimental investigation and multi-response optimization of FFF-printed PETG sandwich structure properties for battery casings. Journal of Computational and Applied Research in Mechanical Engineering (JCARME). ISSN 2251-6549 (In Press)

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Abstract

The increasing demand for strong, lightweight, and thermally efficientbattery casings in electric vehicles has accelerated the exploration ofadditive-manufactured sandwich structures. This research examined howshell thickness and infill density jointly affect the impact strength, mass, andthermal conductivity of sandwich-structured Polyethylene TerephthalateGlycol specimens produced via fused filament fabrication. A factorialexperimental design was used, varying shell thickness (400, 800, and 1200μm) and infill density (20, 50, and 80%). Two-way Analysis of Variance wasapplied to analyze the data statistically. The results revealed that shellthickness significantly influenced all three responses (p ≤ 0.05), increasingimpact strength by approximately 53% and thermal conductivity byapproximately 31% as shell thickness increased from 400 to 1200 μm, at thecost of a nearly 35% increase in mass. Infill density strongly affected massand thermal conductivity, increasing thermal conductivity by approximately127% and mass by approximately 63% from 20% to 80% infill, but had anegligible effect on impact strength (p > 0.05). Then, fractography analysisrevealed distinct failure modes and validated the meso-structure's role inmechanical and thermal performance. Applying desirability function-basedmulti-response optimization, the best configuration was determined to be a1200 μm shell thickness paired with 50% infill density, predicting an impactstrength of 28.57 kJ/m², thermal conductivity of 3.09 W/m·K, and mass of3.34 g. This study provides a strategy for producing lightweight, impact-resistant, and thermally efficient additive-manufactured sandwich structuresfor potential electric vehicle battery casing applications.

Item Type:	Article
Subjects:	T Technology > TJ Mechanical engineering and machinery
Divisions:	Faculty of Engineering > Department of Industrial Engineering Faculty of Engineering > Department of Manufacturing Engineering
Depositing User:	Jaya Suteja 61106
Date Deposited:	28 Sep 2026 02:10
Last Modified:	28 Sep 2026 02:10
URI:	http://repository.ubaya.ac.id/id/eprint/51295

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