An Innovative Approach to Tailor Sandwich Core Structures for Multi-Directional Loading Scenarios
Abstract
:1. Introduction
2. Materials and Methods
2.1. Performance Parameters
2.2. Multi-Direction Comparison Factor
- A positive result shows how much the SMP of Structure 1 is greater than the SMP of Structure 2.
- A negative result shows how much the SMP of Structure 2 is greater than the SMP of Structure 1.
- A result of 0% shows that neither of the structures has a net advantage over the other.
- A value greater than 0 indicates that the structure with greater SMP surpasses the other structure primarily in Loading Direction 1.
- A value lower than 0 indicates that the structure with greater SMP surpasses the other structure primarily in Loading Direction 2.
- A value of 0 indicates, when the MDCF is ≠0, that both loading directions have the same bearing in the structure, with the greater SMP surpassing the other one, and when the MDCF = 0, the value is 0, because neither of the structures has a net advantage over the other.
- Comparing the different iterations of the optimization of a structure.
- Comparing different designs for a specific application.
- Comparing different structures from the literature. To perform such comparisons, the structures should have been studied under the same type of experiment.
2.3. Non-Prismatic Reinforcements
2.4. Manufacturing
2.5. Experimental Setup
3. Results
3.1. NPRH-2
3.2. NPRH-1 and NPRR-3
3.3. MDCF and ACF
4. Discussion
4.1. NPRH-2 Under Multiple Loading Directions
4.2. Multiple Scales of NPRH
4.3. Comparing NPRH-2 with Other Structures
4.4. NPR
5. Conclusions
- In the case of NPRH-2, the Lateral 2 direction had the lowest SEA and earlier densification, possibly due to the NPR’s mass configuration and orientation.
- The peak crushing force (PCF) was not prominent compared to the plateau, with both the PCF and plateau having similar values, in all the curves of the experimental results for three NPRH scales. This suggests that the NPRH potentially does not need pre-crushing, leading to one less step in the manufacturing process, reducing the manufacturing time and costs.
- The three NPRH scales are self-supporting structures that can be manufactured with commercial FFF 3D printers as one part. This improves their manufacturability, reducing the material usage, manufacturing time, and costs. Because external supports are not needed, this enhances the printing repeatability and reduces the standard deviation of the properties of the structures. Designing self-supporting NPR structures can be challenging and less straightforward than designing other simpler structures. Complex geometries may show limitations in printing accuracy at certain scales due to chamfers and small angles.
- The average SEAs of the three NPRH scales were not statistically significantly different. This indicates that increasing the scale does not significantly reduce the structures’ mechanical properties.
- In each of the three multi-directional loading scenarios considered, NPRH-2 presented a greater SEA than both the square honeycomb with internal diagonal walls and the hexagonal honeycomb [12]. NPRH-2’s lateral SEA was more than double the SEA of the hexagonal honeycomb, a prismatic cell.
- In order to compare the mechanical behaviors of different cell geometries under axial and lateral loading, two new comparison factors were developed as part of this work, namely, the MDCF and ACF. These factors are dimensionless and are independent of geometries and materials. They facilitated the comparison of the mechanical properties of the different cells under multi-directional loads. The MDCF and ACF were adapted to the three multi-directional loading scenarios.
- The use of NPRs allows for the possibility of increasing the mechanical properties of sandwich core structures, such as honeycombs, allowing them to be tailored for multi-directional loading applications.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Acknowledgments
Conflicts of Interest
References
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Configuration | Direction 1 Specific Energy Absorption (kJ/kg) | Direction 2 Specific Energy Absorption (kJ/kg) |
---|---|---|
Structure 1 | 31.431 | 23.026 |
Structure 2 | 14.524 | 47.137 |
Configuration | H | G | F | t | d | a | k | n |
---|---|---|---|---|---|---|---|---|
NPRH-1 | 20 | 15.07 | 13.05 | 1.2 | 7.54 | 0.96 | 9.52 | 2.57 |
NPRH-2 | 30 | 22.61 | 19.58 | 1.8 | 11.30 | 1.44 | 14.29 | 3.85 |
NPRH-3 | 40 | 30.14 | 26.11 | 2.4 | 15.07 | 1.92 | 19.05 | 5.14 |
Loading Direction | Energy Absorption (J) | Specific Energy Absorption (kJ/kg) |
---|---|---|
Axial | 176.8 (9.19) | 24.15 (1.24) |
Lateral 1 | 60.34 (5.88) | 8.22 (0.78) |
Lateral 2 | 36.17 (2.65) | 4.94 (0.35) |
Configuration | Energy Absorption (J) | Specific Energy Absorption (kJ/kg) | Mass (g) |
---|---|---|---|
NPRH-1 | 16.74 (1.14) | 7.87 (0.54) | 2.13 |
NPRH-2 | 60.34 (5.88) | 8.22 (0.78) | 7.32 |
NPRH-3 | 124.23 (14.63) | 7.12 (0.89) | 17.47 |
Configuration | Loading Direction | Specific Energy Absorption (kJ/kg) |
---|---|---|
Square | Axial | 17.1 |
Hexagonal | Axial | 19.5 |
Square | Lateral | 5.6 |
Hexagonal | Lateral | 3.8 |
Scenarios | Structure 1 | Structure 2 | D1 | D2 | MDCF (%) | ACF |
---|---|---|---|---|---|---|
A = 0.5 and B = 0.5 | NPRH-1 | Square | Axial | Lateral | 44.0 | −0.08 |
A = 1 and B = 0 | NPRH-1 | Square | Axial | Lateral | 41.2 | 1.00 |
A = 0 and B = 1 | NPRH-1 | Square | Axial | Lateral | 46.8 | −1.00 |
A = 0.5 and B = 0.5 | NPRH-1 | Hexagonal | Axial | Lateral | 70.1 | −0.74 |
A = 1 and B = 0 | NPRH-1 | Hexagonal | Axial | Lateral | 23.8 | 1.00 |
A = 0 and B = 1 | NPRH-1 | Hexagonal | Axial | Lateral | 116.4 | −1.00 |
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Candelaria Caraballo, S.; Menegozzo, M.; Serrano Acevedo, D. An Innovative Approach to Tailor Sandwich Core Structures for Multi-Directional Loading Scenarios. Materials 2025, 18, 599. https://doi.org/10.3390/ma18030599
Candelaria Caraballo S, Menegozzo M, Serrano Acevedo D. An Innovative Approach to Tailor Sandwich Core Structures for Multi-Directional Loading Scenarios. Materials. 2025; 18(3):599. https://doi.org/10.3390/ma18030599
Chicago/Turabian StyleCandelaria Caraballo, Samir, Marco Menegozzo, and David Serrano Acevedo. 2025. "An Innovative Approach to Tailor Sandwich Core Structures for Multi-Directional Loading Scenarios" Materials 18, no. 3: 599. https://doi.org/10.3390/ma18030599
APA StyleCandelaria Caraballo, S., Menegozzo, M., & Serrano Acevedo, D. (2025). An Innovative Approach to Tailor Sandwich Core Structures for Multi-Directional Loading Scenarios. Materials, 18(3), 599. https://doi.org/10.3390/ma18030599