Revolutionizing Lattice Core Sandwich Structures: From Design and Manufacturing to Static Behavior Under Concentrated Load

Abstract

Sandwich panels with core lattice are used in many engineering applications due to their excellent mechanical properties and light weight, there are fundamental challenges facing their use, the most important of which is the separation between the core and the faces, which limits their effectiveness in real conditions. In this study, a practical solution to this problem was presented by manufacturing sandwich panels as a single piece using 3D printing technology, which eliminates the need for traditional adhesives and enhances the structural integrity. The mechanical performance of these new structures under the influence of a concentrated load was analyzed through numerical simulation using ANSYS software and practical tests. The research focused on studying the effect of design factors such as the thickness of lattice struts, thickness of face sheets, and width of lattice unit cell, on the mechanical properties, including deformation, stress, and strain energy. The results showed a high agreement between the numerical simulation and practical tests, confirming the accuracy of the used numerical model. In addition, the results confirmed that the single-piece design leads to a significant improvement in stiffness and reduction of deformation and stresses, while achieving high energy efficiency. It was observed that increasing the thickness of the struts and faces enhances the stiffness, whereas, increasing the width of the lattice unit showed a mixed effect