Novel Geometric Shape to Enhance Bending Resistance in Sandwich Panels: Core Optimization

The mechanical strength of a sandwich composite material is determined by the interaction between its two outer plates and core structure. This study aims to optimize the geometric and mechanical properties of a sandwich composite through a systematic approach using three-dimensional finite element modeling (FEM) combined with the design of experiments (DOE). Three core geometries (square, hexagon, and square-circle) were evaluated to identify the configuration that maximizes load-bearing capacity while minimizing displacement under stress. Each configuration was tested with various fibre orientations (0, 45, and 90) and composite materials (glass/epoxy, boron/epoxy, and graphite/epoxy) in the laminate plates. The results indicate that the square-circle core design, particularly when combined with boron/epoxy plates at a 0 fibre orientation, achieves the highest force resistance with minimal deformation. This optimized configuration provides a robust framework for applications requiring enhanced structural durability, making it a valuable approach for industries such as aerospace, automotive, and civil engineering.