Mechanical Responses of Recycled Core Sandwich Structures With Hybrid Composite Facings: A Study of Quasi‐Static and Dynamic Behavior

ABSTRACT In this study, a sandwich composite structure was developed by combining a recycled, self‐skinned corrugated polypropylene (PP) core with face sheets made from woven hybrid composites of glass, carbon, and aramid fibers. The face sheets were fabricated using the Vacuum‐Assisted Resin Transfer Molding (VARTM) process following an optimized stacking sequence, and subsequently integrated with the core using an EVA‐based thermoplastic adhesive. The performance of the produced structures was evaluated through quasi‐static and dynamic three‐point bending tests, as well as edge compression tests. The findings indicate that the interaction among the different fiber layers enhances interfacial integrity and improves structural stability. The obtained results reveal that integrating the hybrid face sheets with the core enhances the structural durability and positively influences the energy absorption and deformation behavior of the material. The structure developed in this context aims to be evaluated as a potential alternative for producing recyclable, environmentally sustainable, and functional components in the automotive industry, particularly in structures such as electric vehicle battery boxes. Additionally, the study presents a novel approach to the reuse of recycled thermoplastic cores in advanced engineering applications.