Design and fabrication of hierarchical honeycomb structure with in-situ foaming

IF 6.6 1区工程技术 Q1 ENGINEERING, CIVIL

Thin-Walled Structures Pub Date : 2025-09-15 DOI:10.1016/j.tws.2025.113991

Haoyang Yuan , Aijun Huang , Xinni Tian , Xiaoyu Wang , Qiang Gao , Yunlong Tang

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引用次数: 0

Abstract

Achieving high energy absorption with minimal weight remains a key challenge in structural materials design. Drawing on hierarchical architectures observed in natural systems such as woods and bones, this study introduces a second-order hierarchical honeycomb structure fabricated via fused filament fabrication (FFF) process, incorporating solid polylactic acid (PLA) skins and in-situ foamed PLA cores. A design framework was established to explore the effects of geometric parameters and processing conditions, particularly nozzle temperature, on foam morphology and mechanical performance. Through systematic experiments and numerical simulations, it was demonstrated that the proposed solid–foam hybrid structures significantly enhance specific energy absorption (SEA), with the best design achieving up to 63 % improvement over conventional solid PLA honeycombs at equivalent density. Design maps were developed to quantitatively guide structure selection under varying energy absorption and allowable stress constraints. This hierarchical design strategy offers a scalable and tunable pathway for lightweight, impact-resistant structures in advanced engineering applications by tailoring the geometric parameters on each hierarchical level.

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原位发泡分层蜂窝结构的设计与制造

以最小的重量实现高能量吸收仍然是结构材料设计的关键挑战。借鉴在木材和骨骼等自然系统中观察到的分层结构，本研究引入了一种通过熔融长丝制造（FFF）工艺制造的二阶分层蜂窝结构，该结构结合了固体聚乳酸（PLA）外皮和原位发泡PLA芯。建立了一个设计框架，探讨几何参数和加工条件，特别是喷嘴温度对泡沫形态和力学性能的影响。通过系统的实验和数值模拟，证明了所提出的固体-泡沫混合结构显著提高了比能吸收（SEA），在等效密度下，最佳设计比传统固体PLA蜂窝提高了63%。在不同的能量吸收和许用应力约束下，绘制了定量指导结构选择的设计图。这种分层设计策略为高级工程应用中的轻量化、抗冲击结构提供了可扩展和可调的途径，通过定制每个分层级别的几何参数。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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来源期刊

Thin-Walled Structures 工程技术-工程：土木

CiteScore

9.60

自引率

20.30%

发文量

801

审稿时长

66 days

期刊介绍： Thin-walled structures comprises an important and growing proportion of engineering construction with areas of application becoming increasingly diverse, ranging from aircraft, bridges, ships and oil rigs to storage vessels, industrial buildings and warehouses. Many factors, including cost and weight economy, new materials and processes and the growth of powerful methods of analysis have contributed to this growth, and led to the need for a journal which concentrates specifically on structures in which problems arise due to the thinness of the walls. This field includes cold– formed sections, plate and shell structures, reinforced plastics structures and aluminium structures, and is of importance in many branches of engineering. The primary criterion for consideration of papers in Thin–Walled Structures is that they must be concerned with thin–walled structures or the basic problems inherent in thin–walled structures. Provided this criterion is satisfied no restriction is placed on the type of construction, material or field of application. Papers on theory, experiment, design, etc., are published and it is expected that many papers will contain aspects of all three.