“Compression Analysis and Mechanical Assessment of Bioinspired 3D‐Printed Honeycomb Sandwich Structures Using Abaqus‐Based Simulation”

ABSTRACT The primary aim of this study is to investigate the compressive behavior of 3D‐printed sandwich structures inspired by natural honeycomb geometries when subjected to axial loading along different orientations. Using Polylactic Acid (PLA), Acrylonitrile Butadiene Styrene (ABS), and Polyethylene Terephthalate Glycol Modified (PETG) materials, various honeycomb patterns with distinct wall thicknesses and cell sizes were fabricated through Fused Deposition Modeling (FDM)‐based 3D printing. A total of 36 samples were prepared and analyzed under quasi‐static compression to evaluate deformation characteristics. Complementary finite element simulations were conducted using Abaqus software to assess structural responses under controlled loading conditions. Results revealed that both wall thickness and material type significantly influence mechanical performance, with ABS exhibiting superior ductility and dimensional stability. Thicker walls consistently led to reduced deformation across all materials. The study confirms the effectiveness of honeycomb‐inspired sandwich structures in enhancing load‐bearing capacity and energy absorption, offering practical design insights for lightweight, high‐strength applications in automotive, aerospace, and civil engineering domains.