| Abstract Scope |
Topologically Interlocked Materials (TIMs) exhibit exceptional energy absorption, damage tolerance, and mechanical adaptability but are typically limited by complex, assembly-based fabrication methods. This study introduces a one-step approach using Fused Filament Fabrication (FFF) to 3D print TIMs without post-assembly, preserving their interlocking functionality and structural integrity. Various design strategies—including interfacial supports, brackets, ligaments, and mesh reinforcements—were explored to assess their effect on bending performance. Mechanical testing under bending revealed that the printed TIMs exhibited improved load distribution, impact resistance, and energy dissipation compared to traditional counterparts. Additionally, the role of combining flexible (PLA) and rigid (TPU) materials in interfaces and support structures was investigated, showing significant influence on mechanical response. The results demonstrate that FFF enables scalable and efficient production of TIMs, opening pathways for their use in lightweight, protective, and aerospace applications. This work lays the groundwork for further innovations in the additive manufacturing of interlocked structures. |