An Innovative Approach to Tailor Sandwich Core Structures for Multi-Directional Loading Scenarios

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Enhancing the mechanical properties of sandwich core structures is important for crashworthiness applications, including protecting passengers and payloads. Existing structures, such as prismatic cells, present limitations like reduced lateral mechanical properties, among others. Non-prismatic reinforcements (NPRs) are introduced as an alternative to developing core structures tailored for multiple loading scenarios. Several NPR ideas are presented. While additive manufacturing allows for exploring the inner space of core structures with different NPRs, manufacturing such structures may present challenges due to their complexities. One of the NPR ideas was combined with the hexagonal honeycomb, a sandwich core widely used for crashworthiness applications, to create a non-prismatic reinforced honeycomb (NPRH). Utilizing fused filament fabrication, NPRH specimens were manufactured as self-supporting structures at three scales. Quasi-static compression experiments were performed in multiple loading directions. Because comparing structures’ mechanical properties in multiple loading directions simultaneously may present difficulties, the multi-direction comparison factor and the angle comparison factor are presented as alternatives that relate mechanical properties in multiple loading directions and that can be adapted to different loading scenarios. These parameters were used to compare the NPRH with structures from the literature. The NPRH showed greater specific energy absorption, positioning it as a possible solution for multi-loading crashworthiness applications.