The Manufacture of Honeycomb Cores using Fused Deposition Modelling

Dave Pollard*, Carwyn Ward, Guido Herrmann, Julie Etches

*Corresponding author for this work

Research output: Chapter in Book/Report/Conference proceedingConference Contribution (Conference Proceeding)

1 Citation (Scopus)
241 Downloads (Pure)


Sandwich panels are used in many industries, for the advantageous properties of high stiffness, good strength to weight ratio, and impact resistance. Modern manufacturing methods are dominated by manual layup; secondary structure panels often contain multiple core components, complex geometries, and tight placement tolerances. This paper compares cores manufactured using Fused Deposition Modelling (FDM) with conventional Nomex core. FDM is a process of creating complex components from extruded layers of plastic. To analyse the inter-layer bond strength of thin-walled FDM components, tensile behaviour was evaluated for variations in wall thickness. Honeycomb cores were manufactured
using different build patterns, and tested in compression.

It was shown through tensile tests thick-walled FDM components exhibit a more ductile failure with a lower yield point compared to thinner walls. The ultimate tensile stress remained constant across samples. Honeycomb cores produced using FDM were found to have a higher compressive failure force than Nomex, but a lower specific strength. The force-displacement curves of the core failure show a higher energy absorbance of the thicker walled FDM core due to the ductile response.
Original languageEnglish
Title of host publicationProceedings of the 17th European Conference on Composite Materials
PublisherEuropean Conference on Composite Materials, ECCM
Number of pages8
ISBN (Electronic)9783000533877
Publication statusPublished - 26 Jun 2016
Event17th European Conference on Composite Materials, ECCM 2016 - Munich, Germany
Duration: 26 Jun 201630 Jun 2016


Conference17th European Conference on Composite Materials, ECCM 2016
Abbreviated titleECCM 2016


  • Additive
  • Core
  • Honeycomb
  • Layup
  • Manufacture


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