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Honeycombs are commonly used as core materials in sandwich panels, and the core geometry significantly impacts the bending behaviour of these structures. Understanding how core characteristics influence the mechanical properties of sandwich panels is essential. The comparison between different honeycomb sandwich panel configurations is quite complex. This study delves into the intricate comparison between various honeycomb sandwich panel configurations, serving as a benchmark for integral 3D printed panels featuring hexagonal cores in both L- and W-directions, and circular cores. Notably, wrinkling phenomena are observed in the L-direction of the hexagonal cores. Circular cell panels exhibit increased load capacity, flexural modulus, and toughness. Additionally, hexagonal L-core panels demonstrate a higher toughness modulus than their W-core counterparts, making them less rigid yet stronger. Furthermore, L-cell core panels possess a lower density than circular cores, whereas W-cell cores exhibit higher density, compromising their specific mechanical properties. [ABSTRACT FROM AUTHOR]

AbstractThe in-plane auxetic honeycomb sandwich panels (AHSPs) with polyurea-metal laminate (PML) as faceplates were proposed, and their vibration and acoustic properties were investigated. The natural frequency, damping loss factor, sound transmission loss (STL), and sound field pressure distribution were simulated by the finite element, which was then compared with the AHSP without a polyurea layer. The sound insulation properties of the AHSPs with PML faceplates were significantly enhanced due to the viscoelastic energy consumption of the polyurea layer. By changing the thickness of the polyurea layer and adopting different honeycomb geometries, the sound insulation ability of the sandwich plate could be further enhanced. The average STL rose by 2.3–4.7 dB when the polyurea layer thickness was increased, hence significantly improving the noise suppression ability of the AHSPs. When the geometric tilt angle θ of the honeycomb core is −45°, the sandwich panel exhibits superior sound insulation performance. [ABSTRACT FROM AUTHOR]

Additive manufacturing (AM) offers new possibilities to fabricate and design lightweight lattice materials. Due to the superior mechanical properties of these lattice structures, they have the potential to replace honeycombs as cores in sandwich panels. In addition to the advantage of the integral fabrication thanks to AM, additively manufactured lattice core sandwich panels may be also used as heat exchangers, enabling a multifunctional use of the core. To ensure a reliable and safe structure, the mechanical response of lattice core sandwich panels under given load conditions must be predictable. In conventional sandwich panels subjected to compressive loads, the sandwich's global buckling and the face sheets' local buckling are the dominant failure modes. In constrast, core strut buckling may be the critical failure mode in lattice core sandwich panels. Therefore, an analytical 2D model to predict the local buckling of lattice core struts is considered in this study. Furthermore, the critical load for global buckling is obtained based on the first-order shear deformation theory. Thus, the transition from local buckling to global buckling depending on the length-to-thickness ratio is captured by the presented model. The comparison with finite element modeling of the sandwich model with truss cores has proved the accuracy of the derived model. [ABSTRACT FROM AUTHOR]

Material-extrusion-based 3D printing with polylactic acid (PLA) has transformed the production of lightweight lattice structures with a high strength-to-weight ratio for various industries. While PLA offers advantages such as eco-friendliness, affordability, and printability, its mechanical properties degrade due to environmental factors. This study investigated the impact resistance of PLA lattice structures subjected to material degradation under room temperature, humidity, and natural light exposure. Four lattice core types (auxetic, negative-to-positive (NTP) gradient in terms of Poisson's ratio, positive-to-negative (PTN) gradient in terms of Poisson's ratio, and honeycomb) were analyzed for variations in mechanical properties due to declines in yield stress and failure strain. Mechanical testing and numerical simulations at various yield stress and failure strain levels evaluated the degradation effect, using undegraded material as a reference. The results showed that structures with a negative Poisson's ratio exhibited superior resistance to local crushing despite material weakening. Reducing the material's brittleness (failure strain) had a greater impact on impact response compared to reducing its yield stress. This study also revealed the potential of gradient cores, which exhibited a balance between strength (maintaining similar peak force to auxetic cores around 800 N) and energy absorption (up to 40% higher than auxetic cores) under moderate degradation (yield strength and failure strain at 60% and 80% of reference values). These findings suggest that gradient structures with varying Poisson's ratios employing auxetic designs are valuable choices for AM parts requiring both strength and resilience in variable environmental conditions. [ABSTRACT FROM AUTHOR]

In this paper, the non-destructive assessment of thermo-mechanical characteristics of extremely rigid structures made up of natural composites fibers is conducted. Higher-force dynamic mechanical investigation has allowed for new insights, which is not possible with the regularly employed static and impact test methods. Natural fibers made up of composite sandwich panels with aluminum and aramid honeycomb cores are studied. Various panel cores of equal stiffness and damping capabilities are compared over flight frequencies ranging from 1 to 100 Hz. It was discovered that the exhaustion of the natural fiber sandwich panels depends on both the core material and the applied static load. Additionally, temperature sweeps were carried out, and it was discovered that they can identify variations in the post processing of the natural fiber laminated panels and show the variations in the transition temperature of the matrix material. [ABSTRACT FROM AUTHOR]

This study investigates lightweight and efficient candidates for sound absorption to address the growing demand for sustainable and eco-friendly materials in noise attenuation. Juncus effusus (JE) is a natural fiber known for its unique three-dimensional network, providing a viable and sustainable filler for enhanced sound absorption in honeycomb panels. Microperforated-panel (MPP) honeycomb absorbers incorporating JE fillers were fabricated and designed, focusing on optimizing the absorber designs by varying JE filler densities, geometrical arrangements, and MPP parameters. At optimal filling densities, the MPP-type honeycomb structures filled with JE fibers achieved high noise reduction coefficients (NRC) of 0.5 and 0.7 at 20 mm and 50 mm thicknesses, respectively. Using an analytical model and an artificial neural network (ANN) model, the sound absorption characteristics of these absorbers were successfully predicted. This study demonstrates the potential of JE fibers in improving noise mitigation strategies across different industries, offering more sustainable and efficient solutions for construction and transportation. [ABSTRACT FROM AUTHOR]

This study presents an experimental and numerical comparison between the mechanical performance of a lightweight corrugated sandwich panel based on the tea oil camellia shell (TOCS). Hence, TOCS was mixed in two groups with Poplar particles and fibers. After that, in the experimental part, the conventional mechanical tests, including the 3-point bending test, flatwise compression, dowel bearing, and screw resistance, and in the numerical part, finite element analysis (FEA), including the normal, maximum principal, and equivalent (von Mises) stress by Ansys Mechanical software carried out. The specimens for experimental and numerical tests were prepared in transverse and longitudinal directions. Before that, the engineering data (shear modulus, Young's modulus, and Poisson's ratio) for improving the FEA simulation were obtained from TOCS-based flat panels fabricated with a mixture of Poplar particles and fibers. The results of FEA are used to compare the mechanical behavior and failure mechanism with the results of experimental tests. According to the mean values of bending stiffness and maximum bending moment, sandwich panels made with 100% particles demonstrated an advantage in both directions. Nevertheless, the compression strength and screw resistance showed the same trend, but the dowel bearing showed higher values for panels made with fibers. The observed results of equivalent (von Mises) stress indicated a coloration with the results of failure mechanisms. [ABSTRACT FROM AUTHOR]

Abstract This study presents an experimental and numerical comparison between the mechanical performance of a lightweight corrugated sandwich panel based on the tea oil camellia shell (TOCS). Hence, TOCS was mixed in two groups with Poplar particles and fibers. After that, in the experimental part, the conventional mechanical tests, including the 3-point bending test, flatwise compression, dowel bearing, and screw resistance, and in the numerical part, finite element analysis (FEA), including the normal, maximum principal, and equivalent (von Mises) stress by Ansys Mechanical software carried out. The specimens for experimental and numerical tests were prepared in transverse and longitudinal directions. Before that, the engineering data (shear modulus, Young's modulus, and Poisson's ratio) for improving the FEA simulation were obtained from TOCS-based flat panels fabricated with a mixture of Poplar particles and fibers. The results of FEA are used to compare the mechanical behavior and failure mechanism with the results of experimental tests. According to the mean values of bending stiffness and maximum bending moment, sandwich panels made with 100% particles demonstrated an advantage in both directions. Nevertheless, the compression strength and screw resistance showed the same trend, but the dowel bearing showed higher values for panels made with fibers. The observed results of equivalent (von Mises) stress indicated a coloration with the results of failure mechanisms.

Highlights Novel Stitched Foam‐filled Honeycomb Sandwich (SFHS) panels have been fabricated using vacuum‐assisted resin transfer molding to address the weak interfaces between the face sheets and the core in the Foam‐filled Honeycomb Sandwich (FHS) panel. The SFHS panels have shown better load‐bearing capacity and performance characteristics compared to FHS panel after Low‐Velocity Impact (LVI) tests. After the LVI test, MATLAB image processing was used to analyze the impact damage areas and failure mechanisms. In addition, Machine Learning regression algorithms were employed to predict the optimal amount of energy absorbed during low‐velocity impact testing of fabricated panels with a maximum impactor drop height of 700 mm. The results indicated that nylon yarn stitching significantly improved energy absorption and interfacial behavior compared to unstitched honeycomb panels. This research also revealed that SFHS1 panels with adjacent honeycomb cell stitching are more impact resistant, provide increased load carrying capacity, and are cost‐effective. These panels can be utilized by modern engineers to increase economy, durability, and functionality in industrial, automotive, and construction applications. Stitched Foam Filled Honeycomb Sandwich (SFHS) panels, manufactured via resin transfer molding, and eliminates weak interfaces between the face sheets and core. SFHS panels outperformed unstitched panels in load‐bearing and energy absorption during low‐velocity impact, as confirmed by MATLAB image analysis showing reduced damage and failure. Machine learning algorithms particularly polynomial regression model predicted maximum absorption energy precisely with 99.9% accuracy, close to experimental results. SFHS panels can be used in automotive and industrial applications due to their through‐thickness stitching. [ABSTRACT FROM AUTHOR]

Recent advancements in additive manufacturing technologies and topology optimization techniques have catalyzed a transformative shift in the design of architected materials, enabling increasingly complex and customized configurations. This study delves into the realm of engineered cellular materials, spotlighting their capacity to modulate the propagation of mechanical waves through the strategic creation of phononic band gaps. Focusing on the design of sandwich panels with cellular truss cores, we aim to harness these band gaps to achieve pronounced wave suppression within specific frequency ranges. Our methodology combines surrogate modeling with a comprehensive global optimization strategy, employing three machine learning algorithms--k-Nearest Neighbors (kNN), Random Forest Regression (RFR), and Artificial Neural Networks (ANN)--to construct predictive models from parameterized finite element (FE) analyses. These models, once trained, are integrated with Particle Swarm Optimization (PSO) to refine the panel designs. This approach not only facilitates the discovery of optimal truss core configurations for targeted phononic band gaps but also showcases a marked increase in computational efficiency over traditional optimization methods, particularly in the context of designing for diverse target frequencies. [ABSTRACT FROM AUTHOR]

Composite sandwich structures are widely used for their mechanical properties combined to lightweight. However, damage area quantification caused by low velocity impacts represents generally a crucial task in sandwich composites. In the last years, recent advantages of thermographic devices offer new promising and different real-time industrial and engineering applications where lower computation time, accuracy of results and convenient cost are required. The present research deals with the comparison of standard or latest image-processing methods proposed for pulsed thermography regarding their suitability for determining the impact damage area in sandwich materials made of Aluminium core an a GFRP laminated skins. The Infra-Red processed results are compared with the advanced ultrasonic Phased array method commonly employed in the industrial Non-Destructive Testing. Specifically, the damage area quantification is performed by means of an appropriate MATLAB binarization algorithm for the post-processing of acquired thermal and ultrasonic maps. The data results verify the effectiveness of the image-processing thermographic technique combined to advanced processing approaches for the quantitative assessment of impact damage in sandwich component. [ABSTRACT FROM AUTHOR]

Modular construction is becoming famous for buildings because it allows a high degree of prefabrication, with individual modules easily transported and installed. Building envelope optimization is vital as it protects buildings from undesirable external environments by expressly preventing the incursion of outside elements. This research uses a systematic literature review to appraise the characteristics of modular envelope panels, focusing on hygrothermal and energy performance. A total of 265 articles were subjected to rigorous filtering and screening measures. The findings reveal notable inconsistencies in modular envelope terminologies and a lack of consistent performance measures, which present significant challenges for research and development efforts. Furthermore, the results indicate a predominant focus on hygrothermal and energy performance in existing studies, with limited attention to environmental impacts and other performance factors. Moreover, the existing literature primarily addresses modular envelope solutions in temperate climates, offering inadequate information for hot and hot–humid climate contexts. To address these gaps, this study proposes categorizing modular envelope panels into four distinct categories: active, passive, smart, and green/vegetated wall panels. These findings will benefit researchers, architects, building envelope designers, policymakers, and organizations developing building performance-related assessment ratings, standards, and codes. The study suggests adopting the categorization of modular envelope panels provided in this study and developing modular panels suitable for hot and humid climates to fill the existing knowledge gap. [ABSTRACT FROM AUTHOR]

This paper aims to obtain an analytical solution for free vibration and stability analysis of shallow curved sandwich panels made of a porous metal-foam core and nanocomposites reinforced sheets resting on a Winkler-Pasternak elastic foundation. In this regard, two nanocomposites, carbon nanotubes (CNTs) and graphene nanoplatelets (GNPs) are considered for reinforcing the face-sheets. The governing equations are developed by considering the transversal shear strains based on the first-order shear deformation theory (FSDT). The obtained system of differential equations representing the dynamic equilibrium and compatibility of the proposed curved sandwich panels are solved analytically, using the principal of Galerkin method. In order to examine the results of developed formulation, some benchmark examples are adopted from the existing literature and the obtained results corresponding to the considered examples are compared with those are presented in the references. Using the achieved numerical results in the framework of a comprehensive parametric study, the effects of various material and geometrical factors and also various boundary conditions on the natural frequencies and buckling loads of the proposed sandwich panels are assessed. By performing the extensive parametric study it was observed that several results corresponding to the free vibration and stability of the proposed sandwich panels can be achieved by the present method without spending much time for computations. On the contrary, in order to achieve the similar results using the numerical methods, a time-consuming process is required which can justify the novelty of the present work. [ABSTRACT FROM AUTHOR]

In this paper, the non-destructive assessment of thermo-mechanical characteristics of extremely rigid structures made up of natural composites fibers is conducted. Higher-force dynamic mechanical investigation has allowed for new insights, which is not possible with the regularly employed static and impact test methods. Natural fibers made up of composite sandwich panels with aluminum and aramid honeycomb cores are studied. Various panel cores of equal stiffness and damping capabilities are compared over flight frequencies ranging from 1 to 100 Hz. It was discovered that the exhaustion of the natural fiber sandwich panels depends on both the core material and the applied static load. Additionally, temperature sweeps were carried out, and it was discovered that they can identify variations in the post processing of the natural fiber laminated panels and show the variations in the transition temperature of the matrix material.

Sandwich panels are favorable materials for structural or non-structural components due to durability, lightness, and longevity in service life. This study aimed to predict screw withdrawal resistance of the plywood laminated medium-density fiberboard and particleboard, and sandwich panels. In predicting the screw withdrawal resistance, withdrawal load capacity, density, and withdrawal stiffness of the materials in each layer, screw penetration depth, and screw diameter were considered. Moreover, the screw withdrawal strength of the panels was examined. Screw withdrawal tests of panels were conducted according to TS EN 13446 standard. The test results showed a proportional correlation between the density and screw withdrawal strength of the panels. The highest screw withdrawal strength was obtained for sandwich panels made of plywood and medium-density fiberboard (12.51 MPa). Furthermore, the difference between experimental and predicted screw withdrawal resistance changed from 0.20% to 24.86%. Besides, there was no statistically significant difference between the screw withdrawal strength of the top and bottom face-laminated panels. The test results showed that both face laminated panels (sandwich panels) had higher screw withdrawal strength, density, and experimental and predicted screw withdrawal resistance compared to one face laminated panels.

The design of graded and multifunctional lattice cores is driven by the increasing demand for high-performance components in lightweight engineering. This trend benefits from significant achievements in additive manufacturing, where the lattice core and the face sheets are fabricated simultaneously in a single print job. This work systematically compares the mechanical performance of sandwich panels comprising various graded lattice cores subjected to concentrated loads. In addition to graded lattice cores, uniform lattices and conventional honeycomb cores are analyzed. To obtain an optimized graded lattice core, a fully stressed design method is applied. Stresses and displacements are determined using a linear elastic analytical model that allows grading the core properties in a layerwise manner through the core thickness. The analysis indicates the superior performance of graded lattice cores compared to homogeneous lattice cores. However, conventional honeycombs outperform graded lattice cores in terms of load-to-weight ratio and stiffness-to-weight ratio. This study provides valuable insights for the design of lattice core sandwich panels and the advantages of several design approaches. [ABSTRACT FROM AUTHOR]

This paper presents an analysis for the dynamic stability of sandwich beams/wide plates subjected to periodic axial loads. The formulation of the problem is done by use of the Extended High-order Sandwich Panel Theory (EHSAPT). The equations of motion are derived from Hamilton's principle and are expressed in terms of seven generalized displacements. A sandwich panel with simply supported edges is studied as an example, and the equations of motion for a given harmonic n are further derived. Two time-variations for the axial forces, namely, harmonic axial forces and step-wise periodic axial forces, are considered in this work. By considering the features of these two periodic load profiles, Floquet theory and Bolotin's method are adopted to perform the dynamic stability analysis. Sandwich panels with different face-to-core thickness ratios are studied. Stability maps for varying frequency and amplitude of the forces are presented. Numerical examples show that when a sandwich panel is subjected to periodic loads, it is possible that it can experience dynamic instability even when the dynamic loads are much lower than the static critical loads. [ABSTRACT FROM AUTHOR]

This research study the energy absorption performance of aluminum core honeycomb sandwich panel (ACHSP) with filled and empty cores subjected to low-velocity impact testing, with diverse skins; (i) aluminum sheets, (ii) 5-ply epoxy glass composite, and (iii) 5-ply shear thickening fluid (STF)-impregnated glass fabrics. The prepared STF was 35 wt% and the impactor heights was selected at 100 and 500 mm to assess the effect of different impact velocities on the energy absorption capability of STF. The specific energy absorption (SEA) of the STF-filled ACHSP with 5-ply STF-impregnated fabrics skin (height of 500 mm) compared to STF-filled ACHSP with aluminum sheets skin and 5-ply epoxy glass composite skin have increased by 28.38 and 21.79%, respectively. In a fact of truth, when the external force is applied to the STF-filled ACHSP, the fluid transitions from a low-velocity to a high-velocity state instantly. This transition exerts forces on the suspended particles within the fluid. Actually, during the impact, the particles come into close contact and form temporary particle networks or chains. These networks increase the viscosity of the fluid, making it resistant to flow. The energy of the impact is then absorbed by the formation and reformation of these particles' networks. However, the SEA of STF-filled ACHSP at the height of 500 mm to empty ACHSP at the height of 100 mm have decreased significantly, and the energy absorption of STF-filled ACHSPs to corresponding empty ACHSPs have increased remarkably. [ABSTRACT FROM AUTHOR]

Recently, there has been a growing interest in the use of sandwich panels that, beyond handling well-known bending stress, can withstand torsional stresses. This is particularly relevant for wall applications when the panels are equipped with photovoltaic or supplemental curtain wall modules. This research article presents a detailed exploration of the structural behavior of eccentrically loaded sandwich panels, with a specific focus on warping torsion. Experimental and numerical studies were conducted on polyisocyanurate (PU) core sandwich panels, commonly employed in building envelopes. These studies involved various dimensions and material properties, while omitting longitudinal joints. The experimental study provided essential insights and validated the numerical model in ANSYS. Enabling parametric variation, the numerical analysis extends the analysis beyond the experimental scope. Results revealed a high degree of correlation between experimental, numerical, and analytical solutions, regarding the rotation, as well as the normal and shear stress of the panel. Confirming the general applicability of warping torsion in sandwich panels with certain limitations, the study contributes valuable data for applications and design of eccentrically loaded sandwich panels, laying the foundation for potential engineering calculation methods. [ABSTRACT FROM AUTHOR]

A deep understanding of the material parameters and the behavior of sandwich panels, which are used in the construction industry as roof and façade cladding, is important for the design of these construction components. Due to the constant changes in the polyurethane (PU) foams used as a core material, the experimental database for the current foams is small. Nowadays, there is an increasing number of failures of façade and roof panels after installation. This article presents a variety of experimental investigations on sandwich panels from two manufacturers with a core of polyisocyanurate (PIR) rigid foam (density: 40 kg/m3). As part of this study, compression, tension, shear, and bending tests were performed in several spatial directions and over the range required by the standard. The results of the tests showed the orthotropy of the core material and the dependence of the material on the direction and type of load. The stress-strain curves showed linear and non-linear areas. Using the data from this experimental study, a numerical model was implemented which utilized the Hill yield criterion to represent the orthotropy of the core material. The present investigation suggests that the classical von Mises failure criterion, used in many studies, is not suitable for the foam system applied in these sandwich panels. Instead, the Tsai–Wu criterion is more appropriate for defining the failure stresses. [ABSTRACT FROM AUTHOR]

Featured Application: The design and manufacturing of sandwich solutions using FRCM vegetal fabric skins improve sustainability because they provide solutions with a lower global carbon footprint. The utilization of the vegetal fabric-reinforced cementitious matrix (FRCM) represents an innovative approach to composite materials, offering distinct sustainable advantages when compared to traditional steel-reinforced concrete and conventional FRCM composites employing synthetic fibers. This article introduces a design for sandwich solutions based on a core of extruded polystyrene and composite skins combining mortar as a matrix and diverse vegetal fabrics as fabrics such as hemp and sisal. The structural behavior of the resulting sandwich panel is predominantly driven by the interaction between materials (mortar and polyurethane) and the influence of shear connectors penetrating the insulation layer. This study encompasses an experimental campaign involving double-shear tests, accompanied by heuristic bond-slip models for the potential design of sandwich solutions. The analysis extends to the examination of various connector types, including hemp, sisal, and steel, and their impact on the shear performance of the sandwich specimens. The results obtained emphasize the competitiveness of vegetal fabrics in achieving an effective composite strength comparable to other synthetic fabrics like glass fiber. Nevertheless, this study reveals that the stiffness of steel connectors outperforms vegetal connectors, contributing to an enhanced improvement in both stiffness and shear strength of the sandwich solutions. [ABSTRACT FROM AUTHOR]

Honeycomb panels manufactured from wood and paper materials promote a high-value utilization of wood resources. However, the poor mechanical properties and uncommon thicknesses (32 and 40 mm) of paper honeycomb panels limit their application and promotion in the panel furniture industry. Hence, numerous attempts have been made to develop high-strength and low-density wood sandwich composites for the frames and partitions of cabinet furniture. This paper describes a method for manufacturing lightweight sandwich panels (18 mm thickness) with auxetic cores, made of fast-growing poplar. The mechanical properties of the panels and the negative Poisson's ratio of the perforated sheet cores were determined by three-point bending and uniaxial compression tests. The lower density, higher modulus of elasticity, and bending strength suggest that the developed panel is a good substitute for traditional wood-based panels. A numerical model for panels in bending tests is proposed and validated against the experimental analysis results. These investigations facilitate further research into optimizing the sandwich panel structure and its applicability in the architectural and furniture industry. Graphical Abstract [ABSTRACT FROM AUTHOR]

This study prepares composite panels with three Polylactic acid (PLA)-based materials via the multi-material fused filament fabrication method. The influences of four processing parameters on the mechanical properties of 3D-printed samples are investigated employing the Taguchi method. These parameters include the relative volume ratio, material printing order, filling pattern, and filling density. A "larger is better" signal-to-noise analysis is performed to identify the optimal combination of printing parameters that yield maximum bending strength and bending modulus of elasticity. The results reveal that the optimal combination of printing parameters that maximizes the bending strength involves a volume ratio of 1:1:2, a material sequence of PLA/foam-agent-modified eco-friendly PLA (ePLA-LW)/glass fiber-reinforced eco-friendly PLA (ePLA-GF), a Gyroid filling pattern, and a filling density of 80%, and the optimal combination of printing parameters for maximum bending modulus involves a volume ratio of 1:2:1 with a material sequence of PLA/ePLA-LW/ePLA-GF, a Grid filling pattern, and 80% filling density. The Taguchi prediction method is utilized to determine an optimal combination of processing parameters for achieving optimal flexural performances, and predicted outcomes are validated through related experiments. The experimental values of strength and modulus are 43.91 MPa and 1.23 GPa, respectively, both very close to the predicted values of 46.87 MPa and 1.2 GPa for strength and modulus. The Taguchi experiments indicate that the material sequence is the most crucial factor influencing the flexural strength of the composite panels. The experiment result demonstrates that the flexural strength and modulus of the first material sequence are 67.72 MPa and 1.53 GPa, while the flexural strength and modulus of the third material sequence are reduced to 27.09 MPa and 0.72 GPa, respectively, only 42% and 47% of the first material sequence. The above findings provide an important reference for improving the performance of multi-material 3D-printed products. [ABSTRACT FROM AUTHOR]

Recent advancements in additive manufacturing technologies and topology optimization techniques have catalyzed a transformative shift in the design of architected materials, enabling increasingly complex and customized configurations. This study delves into the realm of engineered cellular materials, spotlighting their capacity to modulate the propagation of mechanical waves through the strategic creation of phononic band gaps. Focusing on the design of sandwich panels with cellular truss cores, we aim to harness these band gaps to achieve pronounced wave suppression within specific frequency ranges. Our methodology combines surrogate modeling with a comprehensive global optimization strategy, employing three machine learning algorithms—k-Nearest Neighbors (kNN), Random Forest Regression (RFR), and Artificial Neural Networks (ANN)—to construct predictive models from parameterized finite element (FE) analyses. These models, once trained, are integrated with Particle Swarm Optimization (PSO) to refine the panel designs. This approach not only facilitates the discovery of optimal truss core configurations for targeted phononic band gaps but also showcases a marked increase in computational efficiency over traditional optimization methods, particularly in the context of designing for diverse target frequencies.

Material-extrusion-based 3D printing with polylactic acid (PLA) has transformed the production of lightweight lattice structures with a high strength-to-weight ratio for various industries. While PLA offers advantages such as eco-friendliness, affordability, and printability, its mechanical properties degrade due to environmental factors. This study investigated the impact resistance of PLA lattice structures subjected to material degradation under room temperature, humidity, and natural light exposure. Four lattice core types (auxetic, negative-to-positive (NTP) gradient in terms of Poisson’s ratio, positive-to-negative (PTN) gradient in terms of Poisson’s ratio, and honeycomb) were analyzed for variations in mechanical properties due to declines in yield stress and failure strain. Mechanical testing and numerical simulations at various yield stress and failure strain levels evaluated the degradation effect, using undegraded material as a reference. The results showed that structures with a negative Poisson’s ratio exhibited superior resistance to local crushing despite material weakening. Reducing the material’s brittleness (failure strain) had a greater impact on impact response compared to reducing its yield stress. This study also revealed the potential of gradient cores, which exhibited a balance between strength (maintaining similar peak force to auxetic cores around 800 N) and energy absorption (up to 40% higher than auxetic cores) under moderate degradation (yield strength and failure strain at 60% and 80% of reference values). These findings suggest that gradient structures with varying Poisson’s ratios employing auxetic designs are valuable choices for AM parts requiring both strength and resilience in variable environmental conditions.

This study investigates lightweight and efficient candidates for sound absorption to address the growing demand for sustainable and eco-friendly materials in noise attenuation. Juncus effusus (JE) is a natural fiber known for its unique three-dimensional network, providing a viable and sustainable filler for enhanced sound absorption in honeycomb panels. Microperforated-panel (MPP) honeycomb absorbers incorporating JE fillers were fabricated and designed, focusing on optimizing the absorber designs by varying JE filler densities, geometrical arrangements, and MPP parameters. At optimal filling densities, the MPP-type honeycomb structures filled with JE fibers achieved high noise reduction coefficients (NRC) of 0.5 and 0.7 at 20 mm and 50 mm thicknesses, respectively. Using an analytical model and an artificial neural network (ANN) model, the sound absorption characteristics of these absorbers were successfully predicted. This study demonstrates the potential of JE fibers in improving noise mitigation strategies across different industries, offering more sustainable and efficient solutions for construction and transportation.

This article deals with the dynamic penetration of 3D‐printed panels with auxetic and conventional honeycomb unit cell‐based cores. The geometry of the unit cells and their periodic assembly in the resulting lattices are selected to ensure the same relative density and overall weight of the individual sample types. Such a similarity of both specimen types allows for the evaluation of differences between conventional and auxetic lattices in terms of penetration characteristics and deformation energy mitigation properties. Dynamic penetration of the samples is performed using a fully strain‐gauge instrumented open Hopkinson pressure bar at three impact velocities resulting in three loading scenarios. All the performed experiments are captured by two optical cameras for detailed observation and to track the impactor movement using digital image correlation. The force‐penetration depth relation is used to evaluate the elastic and postyield compression characteristics of the lattices together with their deformation energy mitigation capabilities. The results show that the main differences in the deformation response of the lattices consist of lower overall stiffness and effective yielding of the auxetic lattices at a higher penetration depth. Numerical simulation using an explicit solver is performed to analyze the deformation mechanism of the individual core types. [ABSTRACT FROM AUTHOR]

Scaling is a widely used concept in impact and explosion engineering which is mainly utilized to predict the response behaviour of large-scale mechanical structures by conducting experiments on scaled trial models. However, the practical application of currently available conventional scaling methodologies for impact and explosive processes are significantly restricted by their inability to properly capture the scale effects of strain rate and strain hardening. Also, they are suffering from an insufficient number of independent degrees of freedom. Furthermore, the zeroth-order finite similitude theory, which can annihilate the non-scalability of rate and hardening effects, doesn't provide us with efficient scaling methods when the investigated structure is made out of different materials. More precisely, the zeroth-order finite similitude theory and the classical dimensional analysis, which are suffering from a limited number of independent degrees of freedom, cannot scale the elastic-plastic behaviour represented by different parts of a structure made out of different materials. In other words, classical scaling methodologies including dimensional analysis and even the zeroth-order finite similitude theory cannot fix two different features having the same unit using different degrees of freedom, which make them useless for structures made of more than one material such as bi-material sandwich panels. In the presented paper, a new scaling methodology is developed based on the recently proposed first-order finite similitude theory which for the first time enables us to capture the rate dependent plastic behaviour of an impacted structure made out of two different materials. A sandwich panel made of two different materials which is subjected to an impact loading is considered as the case study in order to investigate the efficiency of the proposed first-order based scaling technique. The numerical results are determined using Abaqus finite element software in which the Johnson-Cook constitutive equation is utilized to take into account the rate and hardening effects on the initial yield stress. The results reveal that the behaviour of impacted full-scale bi-material sandwich panels can be predicted with a high accuracy when the extra degree of freedom provided us with the first-order finite similitude (i.e. R 1) is set to vary between −1 and 1 (i.e. − 1 ≤ R 1 ≤ 1). Furthermore, it is found that the pure mechanical and thermo-mechanical behaviour of the impacted core honeycomb are highly accurately predicted using scaled-down trial models which are made from dissimilar materials and designed based on the zeroth-order finite similitude theory. [ABSTRACT FROM AUTHOR]

On the flexural buckling of sandwich panels Sandwich panels are one of the leading systems for building envelopes in industrial and commercial construction. Other areas of applications are cold storage rooms, which are realized exclusively from sandwich panels without any substructure or primary structure. Thereby, the sandwich panels, which are used as wall panels, are subjected to axial loads. A design concept of sandwich panels under axial loading based on stress verifications can be found in the draft of the new Eurocode 3 standard EN 1993‐7 "Design of steel structures – sandwich panels". A design concept based on the geometrical and structural imperfections and the actual load‐bearing capacity of the panels is neither included in the literature nor in the draft of the new standard. In the present work, investigations on flexural buckling of sandwich panels are presented. A method is presented which can be used in the future for the development of buckling curves of sandwich panels. [ABSTRACT FROM AUTHOR]

Tests on sandwich façades as a basis for seismic design As part of an ongoing research project, the performance of lightweight metal façade elements under in‐plane loading was investigated to assess their cyclic behavior, dissipation capacity and functionality during seismic events. As preliminary investigations showed, metal wall and roof elements contribute to the stiffening of the overall structure, and thus to the change of the eigen period compared to the primary structure, which can lead to increased seismic loads to be applied acc. to the response spectrum method. Based on this, a new behavior‐based approach considering the contribution of lightweight metal building envelopes can be developed to determine the improved resilience of structures and the effect of a damaging earthquake on the building envelope performance. This paper includes: (i) a brief state of the art, (ii) a presentation of the research project, (iii) the experimental program, (iv) the detailed experimental setup, (v) the system response under monotonic and cyclic loading, (vi) the main results, (vii) an overview of the numerical investigations and ongoing and future research activities. [ABSTRACT FROM AUTHOR]

Cold stores with sandwich panels Cold stores are indoor constructions, which are indispensable for the storage of foods. The rising demand for larger storage‐spaces in the distribution centers of the food‐retailers lead to steel‐lightweight cold stores with dimensions of L × W × H = 50 m × 20 m × 16 m, which require a proper structural design. Because of their excellent insulating properties, mainly sandwich panels are used for the construction of cold stores. The detailed designs are demanding, as they require comprehensive thermal and executional optimization. Hence, they often need to be considered in the design and calculation process. The ceiling and wall panels may be considered as diaphragms for the spatial stiffening if the corresponding design and execution rules are respected. If in addition, the wall elements, transferring the ceiling loads, are designed regarding the additional stresses due to second order theory, cold rooms made of sandwich panels, may be carried out without any substructure. The draft of the new standard – prEN 1993‐7 "Design of steel structures – sandwich panels" – provides a corresponding design method. Proven execution details and calculation examples for panels as diaphragms and compression supports are explained below. [ABSTRACT FROM AUTHOR]

Lightweight building steel envelop systems with bio‐based insulation – conservation of resources and reduction of CO2 emissions The aim of the research project presented below is to develop five building envelope systems made of low‐carbon steel and innovative use of wood fibre insulation. Three sandwich panels (pitched roof, flat roof, façade), a double‐skin façade and a façade cladding (cassettes) will be developed. The project includes a series of tests to investigate all relevant properties of the systems: load‐bearing behavior, fire behavior, thermal insulation, acoustics, air‐, water‐ and vapor‐permeability. In addition, two full‐scale prototypes were built to study the behavior of the systems under real conditions. The determination of LCA indicators and a comparison in terms of carbon footprint (GWP) with conventional systems using an existing office building as a reference will also be carried out. An economic comparison between the expected delivery and installation price of the five innovative systems and that of the existing conventional systems is planned. The production of the sandwich panels can be easily integrated into the current production lines. [ABSTRACT FROM AUTHOR]

The research presented in this paper is about the mechanical properties of fiber-reinforced alkali-activated slag cementitious sandwich panels with different types and amounts of admixtures. The mechanical properties, drying shrinkage properties, and micro-morphology were used to determine the optimal ratio of the admixtures. The results show that the alkali-activated slag sandwich panels have the characteristics of light weight, high strength and excellent thermal insulation, and the factors such as magnesium oxide, expansion agent and solution temperature have significant influence on their mechanical properties and dry shrinkage. This paper provides a theoretical basis and experimental data for the preparation process and application of alkali-activated slag sandwich panels. [ABSTRACT FROM AUTHOR]

Despite the extensive research on renewable resources (RR) and their potential applications in composite materials and sandwich structures, there remains a significant dearth of life cycle assessment (LCA) studies that comprehensively evaluate the efficacy of RR in mitigating environmental impacts (EI). To bridge this gap, the present study aims to investigate twelve different designs of sandwich panels, specifically referred to as Fibre Metal Laminates (FML). These FML combine aluminium skins (2024-T3 and 1200-H14), polymer matrices (Epoxy, Polyester, and Castor oil Bio-PU), natural fibres (Sisal, Coir, and Cynodon spp.), surface treatments for aluminium skins (sanding, NaOH, and Washprimer), and treatments for natural fibres (Ground, NaOH-treatment and untreated). A cradle-to-gate LCA is conducted, and the inventories are modelled using the OpenLCA 1.6.3 and ecoinvent 3.9 cut-off regionalized database. EI are evaluated in twelve categories, including climate change, fossil and nuclear energy use, freshwater (acidification, ecotoxicity and eutrophication), human toxicity (cancer and non-cancer), mineral resources use, ozone layer depletion, particulate matter formation, photochemical oxidant formation, and terrestrial acidification. Impact World+ method for Latin America version 1.251 is employed to calculate EI. Nine Eco-efficiency indicators and trade-off analyses are evaluated to gain insights into design decision outcomes. Among the various panels considered, FML12, manufactured with aluminium alloy 1200-H14 treated only with sanding, castor oil biopolymer and untreated coir fibres, present the most consistent eco-efficiency indicators. The reference scenario considers the average characteristics of FML (both environmental and mechanical) for trade-off analysis. Despite the fifty percent chance of better performance, FML12 is the only panel that shows higher mechanical performance and lower EI compared to the reference scenario. The importance of this article lies in the novel results obtained using the proposed eco-efficiency indicators, which can be expanded in further studies on the topic.

This investigation aims to present a high-strength sandwich core with functionally graded multi-morphology lattice inner structures through vat photo-polymerization additive manufacturing (AM). The five better strut-based designs based on [1], are considered here. All printed specimens have been fabricated from photopolymer resin to ensure manufacturability in a digital light processing (DLP) 3D printer. Firstly, the resin and structural characteristics have been examined. Simultaneously, the lattice core is divided into three regions based on the von Mises stress distribution and tensile and compression responses in finite element analysis (FEA). Based on the mechanical responses of the beam-based structures, these topologies have been applied in each region in an optimal fixed relative density distribution, considering different steps and types. This proposed technique is numerically investigated and experimentally validated using a three-point bending test. As a result, the optimized core demonstrated a 96% increase in maximum fracture force and a 174% increase in stiffness compared to the homogeneous body. Additionally, it exhibited a different deformation mode than the single morphology under similar conditions. These significant findings indicate that this approach provides a new perspective on a high-strength design involving more than three morphologies, and it is faster than computational topology optimization processes.

This paper presents investigations on the load‐bearing behaviour of sandwich panels under bending load and axial load. The sandwich panels investigated here have the special feature that they consist of two face sheets, a polyurethane core and two integrated reinforcement profiles. These integrated profiles allow the stiffness of the panels to be significantly increased, resulting in a delayed wrinkling failure and thus opening up new fields of application. Experimental results from bending tests are presented. From these results, analytical approaches are then described that can be used to predict the load‐bearing behaviour under axial loading. In addition, the test setup is described, which will be used in the future for the experimental investigation of the panels under axially loading. [ABSTRACT FROM AUTHOR]

Strong earthquake loads can cause significant damage to buildings, but even moderate earthquakes with higher return periods are socially relevant as they may cause both infrastructure and economic failures. In an ongoing German nationally funded research project, the behavior of facade elements in lightweight metal construction under in‐plane deformation is currently being investigated with the aim to assess the response and the energy dissipation capacity in the case of seismic events. As past research results indicate the contribution of wall and roof elements to the stiffening of buildings, with the possible consequence of increased earthquake loads due to the natural frequency change, a novel approach for increased resilience of structures with building envelopes in lightweight metal construction may be developed. On the basis of a series of experimental tests, under monotonic and cyclic loading, the effects of in‐plane deformation were studied separately from external influences such as wind and thermal loads. This paper presents: (i) a brief state of the art; (ii) a description of the research framework; (iii) the experimental program; (iv) the specimen configuration, test set‐up, loading protocol and instrumentation; (v) the response under monotonic and cyclic loading; (vi) the main conclusions, as well as the ongoing and future research activities. [ABSTRACT FROM AUTHOR]

The total shear force induced on a profiled sandwich panel by an external load is distributed between the profiled face and core. Sandwich panel with a discrete core material such as mineral wool consists of multiple transverse lamella joints across the full width of the panel, affecting the overall shear performance of the panel as these joints have negligible resistance to shear. Additionally, in some cases the core material is partially bonded only to the lower flange of the profiled face which increase the concentration of stresses in the bonded area leading to the crushing of the core on the support. This work studies the distribution of shear force in mineral wool core sandwich panels with one profiled face utilizing a shear beam test on a specimen cut from the panel including the profiled part. Based on the results and failure modes obtained, this work investigates the behavior and role of the profiled face on the shear resistance of profiled sandwich panels. The distributed shear force between the core and profiled part obtained from the shear beam tests are compared with full‐scale tests suggested by the European Standard EN 14509:2013, thus, exploring the applicability of the devised shear beam test method for assessing the shear properties of profiled sandwich panel. [ABSTRACT FROM AUTHOR]

Lightweight steel constructions made of sandwich panels are an economical solution for wall and roof claddings, especially in industrial construction. The panels consist of two thin sheets of steel and a core with thermal insulating properties. In the mounted state and at high temperatures on the outer face of the panel, damage to the components may occur due to blister formation. In a current research project, the influence of defects in sandwich panels with a PIR‐foam core is examined. This article presents the results of experimental tests regarding the influence of various parameters, such as face temperature, production defects and design of the longitudinal joint on blistering in sandwich wall panels with a PIR‐core. The aim is to identify the necessary conditions for the occurrence of blisters. Using an optical strain measuring method (Digital Image Correlation), the temperature‐induced deformations and strains in the covering nose of sandwich wall panels with hidden fastening are measured and will be analyzed with regard to blistering. First results reveal a significant dependence on the geometry and design of the covering nose. [ABSTRACT FROM AUTHOR]

Sandwich panels in the construction industry are used as roof and facade elements and usually consist of two thin face layers of steel and a thicker core of polyurethane (PU) or mineral wool in between. The PU core material is constantly being further developed. In addition to improvements in the physical properties, this further development also leads to changes in the mechanical properties. As a result, the design rules that were established for older foam systems must be reviewed at regular intervals. There is a great need for research into the temperature‐dependent behavior of the foam system. As these elements are used as roof and facade elements, they are directly exposed to climatic conditions. High temperatures are generated on the cover sheets due to solar radiation. The PU rigid foam changes its mechanical properties in this temperature range. Tests on small parts and components show a change in the stiffnesses and strengths, as well as the load‐bearing behavior under elevated temperature. Consideration of the temperature in the design is therefore of great importance. In view of the continuous further development of the foam system, statements regarding the core material from older research must be reconsidered. [ABSTRACT FROM AUTHOR]

The paper presents results of a research on robustness of sandwich panels subjected to the accidental load – impact blast wave. The accidental design situation is understood as an unexpected explosion of gas cylinders located in the neighbourhood of the building. Full‐size sandwich panels with lightly profiled, thin‐walled, steel facings and thick softcore were used in the experiments. The conducted field tests allowed for FE model validation in Abaqus/CEA environment. During the experiments, the two high‐speed cameras have been used to record the behavior of the sandwich panel. Furthermore, the failure mechanisms of the sandwich panels and fasteners were also revealed. The research outcomes are based on both field experiments and numerical simulations. [ABSTRACT FROM AUTHOR]

The paper presents theoretical, experimental and numerical studies on the thermal behavior of mineral wool used in sandwich panels. The aim of this study is to investigate the thermal properties of mineral wool at elevated temperatures and provide a simple model that would allow us to determine the heat propagation in sandwich panels during a fire. The paper proposes a new method to experimentally evaluate thermal diffusivity, derived from theoretical premises. Experiments are conducted in a laboratory furnace where specimens are placed and temperatures inside specimens are measured. Different methods are used to process the test results and calculate the thermal diffusivity of mineral wool. Finally, a numerical analysis of heat transfer using the finite element method (FEM) is performed to validate the obtained thermal properties. [ABSTRACT FROM AUTHOR]

The explosion products, such as shock waves, fragments and heat energy formed by explosion, act on the plate structure, which may cause structural damage, material failure and even phase transformation of material. In this paper, the damage mechanism and protective effect of near-field blast load on sandwich structure based on foam-nickel core material were studied. Firstly, the near-field explosion test was conducted to investigate the blast response of the foam-nickel sandwich structure subjected to blast shock from 8701 explosive at near-field position. The deformation characteristics and stress history of the sandwich structure on the acting location of blast load were carefully investigated via experimental methods. A finite element model of near-field explosion was established for effective numerical modelling of the dynamic behaviour of the sandwich structure using the explicit dynamics software ANSYS/LS-DYNA for more comprehensive investigations of the blast shock response of the sandwich structure. The finite element model is reasonable and validated by mesh independence verification and comparing the simulated response behaviour to that from the experimental results for the sandwich structure subjected to near-field blast load. On this basis, the damage mechanism and protection effect of the near-field explosion impact on foam-nickel cores with different density and porosity are simulated more systematically. The investigated results from the experiments and a series of numerical simulations show the large deformation effect due to the extensive energy absorption, which suggests that the sandwich structure based on foam-nickel core material may be expected to become a new choice of protective structure under near-field blast load. [ABSTRACT FROM AUTHOR]

Additive manufacturing enables the fabrication of strut-based lattices that consist of periodic representative volume elements (RVE) and can be used as cores in sandwich panels. Due to the design freedom provided by additive manufacturing, the lattice strut diameter may vary through the lattice. Thus, the diameter distribution can be adapted to the stress variation in the sandwich core to achieve an efficient core design and avoid oversizing the core. Such grading approaches are required when the core is subjected to localized loads, e.g., near support points and load application areas. In this work, an analytical model is derived to determine stresses and deformations in lattice struts of RVE-based graded lattice cores in elastic sandwich panels using homogenization and dehomogenization methods. In contrast to already available models, the analytical model presented in this work allows grading the lattice strut diameter both along the sandwich length and through the core thickness. Furthermore, local stresses in the lattice struts caused by concentrated load application can be captured adequately by the present model. To highlight the benefits of graded cores, the strut stress distribution in graded cores is compared to the stress distribution in homogeneous cores. [ABSTRACT FROM AUTHOR]

Origami foldcore structures can be used in thin-walled sandwich panels to provide unique advantages over traditional honeycomb structures. For instance, their continuously connected space is available for flowing through cooling liquid or compact pipeline placement. However, origami foldcores suffer from relatively low-energy absorption. This paper proposes a new design of energy-absorbing foldcore structures for sandwich panels, including the geometric design, experimental tests, numerical parametric study, and theoretical estimation of energy absorption. Origami initiators are introduced to the Miura foldcores to induce a failure mode with more transverse folds, which is not common for regular foldcore structures. As a result, 60% higher energy absorption and tunable load uniformity can be achieved. [ABSTRACT FROM AUTHOR]

The paper presents the basic principles of static calculations of plates with discrete filling–ribs; the method is based on the analytical solution of the problem of the stress state of a ribbed plate. The bottom line is to use special discontinuous functions at the stage of writing the initial assumptions of differential equations, as well as in the process of solving them due to the nature and physical meaning of the problem. [ABSTRACT FROM AUTHOR]

Shape memory alloys, especially in the form of wire, can provide structures with magnificent improvements in buckling and frequency responses. The SMA's ability to recover its original shape can produce a sizable amount of recovery stress, resulting in enhancing natural frequency and critical temperature and lowering the maximum deflection of structures. In this study, in addition to considering the effects of SMA presence in double-curved sandwich plate on the aforementioned characteristics, the influences of heat treatment of curing SMAs on their properties, calculated by differential scanning calorimetry (DSC) and tensile testing, and sandwich structures will be considered. Furthermore, the effects of recovery stress, the volume fraction, and the position of SMA wires on thermal and mechanical stability will be studied. The Boyd & Lagoudas SMA constitutive model is utilized in the ABAQUS UMAT subroutine.

The design of graded and multifunctional lattice cores is driven by the increasing demand for high-performance components in lightweight engineering. This trend benefits from significant achievements in additive manufacturing, where the lattice core and the face sheets are fabricated simultaneously in a single print job. This work systematically compares the mechanical performance of sandwich panels comprising various graded lattice cores subjected to concentrated loads. In addition to graded lattice cores, uniform lattices and conventional honeycomb cores are analyzed. To obtain an optimized graded lattice core, a fully stressed design method is applied. Stresses and displacements are determined using a linear elastic analytical model that allows grading the core properties in a layerwise manner through the core thickness. The analysis indicates the superior performance of graded lattice cores compared to homogeneous lattice cores. However, conventional honeycombs outperform graded lattice cores in terms of load-to-weight ratio and stiffness-to-weight ratio. This study provides valuable insights for the design of lattice core sandwich panels and the advantages of several design approaches.