Load-dependent optimization of honeycombs for sandwich components - new possibilities by using additive layer manufacturing

Due to their producible geometric complexity, additive layer manufacturing (ALM) processes show a high potential for the production of lightweight components. ALM processes enable the realization of bionic components like honeycombs. Hence it is possible to perform load-dependent optimization of honeycombs depending on the outer boundary conditions. This optimization is based on a closed-loop, three steps methodology: Firstly, every honeycomb cell is adapted conform to the surface of the part. Secondly, the structure is optimized related to lightweight design. Achieving a homogeneous stress distribution in the part is possible by varying the wall thickness, honeycomb diameter and honeycomb amount depending on subjected stresses and strains. Thirdly, the integration of functional components like coupling, bearing carriers or shear walls is done directly into the honeycomb core. By using all these steps as an iterative process, it is possible to reduce the volume of sandwich components about 60 percent compared to conventional approaches.