Low-velocity impact response of hybrid core sandwich panels with spring and strut cores filled with resin, silicone, and foam

Advancements in the load-bearing capacity of composite panels open doors to high-performance applications. The integration of additive manufacturing allows for the creation of intricate core designs effortlessly. Hybrid cores, combining structural elements with infill materials, play a crucial role in enhancing panel impact resistance while maintaining its low weight. This study compares sandwich panels incorporating spring and octet strut structural elements infused with different materials—silicon, foam, and epoxy resin—evaluating their energy absorption capabilities. Additive manufacturing is employed to produce these panels with structural elements then subsequently filled with infills. The drop tower test is utilized to experimentally assess panel behavior under low-velocity impact. Design of experiments and statistical analysis are used to examine the influence of core height, impact height, core geometry, and filling type on the damaged area and impactor penetration. Results showed that the strut-based structure performed better than other structures in preventing penetration, with a damaged area reduction from 501.45 to 301.58 m² compared to the spring core. The addition of foam or silicon reduced the impact damage to the front and the back sheets, with silicon infills proving to be the most effective, reducing penetration by reducing penetration by about 60%. The depth of impact was measured, with results indicating that the truss core displayed the smallest specific depth of penetration. A decision tree model predicted that a sandwich panel with a spring core would have a 100% chance of perforation while a filled core showed a significantly reduced penetration risk.