Construction of Isotropy-Enhanced Honeycomb and Its Deformation Behaviors in Multi-Directions

Honeycomb structures are widely constructed as cores in sandwich panels with lightweight characteristics and excellent out-of-plane properties. However, their in-plane performances are significantly inferior. This research proposed a novel isotropy-enhanced honeycomb (IEH) with interleaved layers, which is constructed by offsetting the initial seed distributions across layers and then generating hexagonal cells via Voronoi tessellation. Numerical models with three layer-to-layer interval gradients were developed for simulations, and corresponding samples were additively manufactured for experimental validations. The in-plane and out-of-plane performances of IEH and the regular hexagonal honeycombs (RHHs) were comprehensively compared and investigated from quasi-static compression, energy absorption, mechanical properties, and dynamic loading. The results demonstrated that the IEH extremely enhances the in-plane properties by around 500% compared to the RHH, including stiffness, strength, plateau stress, and specific energy absorption (SEA). Although the improvements come at the expense of a partial reduction in out-of-plane stiffness, strength, and SEA, the in-plane performances of IEH reach approximately 70% of their out-of-plane performances, greatly improving the structural isotropy. Introducing layer-to-layer interval gradient leads to a slight reduction in out-of-plane mechanical properties while improving the early-stage deceleration under impact. These findings promote the considerable potential of sandwich panels utilizing IEH cores for applications requiring enhanced resistance to multi-directional impacts.