LPBF-Produced Elastomeric Lattice Structures for Personal Protection Equipment: Mechanical Performance Versus Comfort-Related Attributes

This study focuses on the energy absorption and wearer comfort attributes of regular lattice structures fabricated by laser powder bed fusion from two elastomeric materials, namely TPU1301 and TPE300, for use in personal protective equipment (PPE). This study compares Body-Centered Cubic (BCC), Face-Centered Cubic (FCC) and Kelvin (KE) lattice structures with density varying from 0.15 to 0.25 g/cm³, cell size varying from 10 to 14 mm and feature size varying from 1 to 3 mm. Quasi-static and dynamic compression testing confirmed that among the studied geometries, KE structures printed with TPE300 powders provide the best combination of reduced peak acceleration and increased compliance, thereby improving both safety and comfort. Using the protection–comfort maps built on the basis of this study enables the design of lightweight and compact protective structures. For example, if a safety layer protecting a 100 mm² surface area can be manufactured from either TPE300 or TPU1100 powders using either KE or FCC structures, the KE TPE300 layer will be 1.5 times thinner and 2.5 times lighter than its FCC TPU1301 equivalent. The results of this study thus provide a basis for the optimization of lattice structures in 3D-printed PPE to meet both service and manufacturing requirements.