Symmetrical Finite Element model for out-of-plane crushing of Nomex honeycomb structure

The computational cost of Finite Element (FE) simulation of a honeycomb structure under compression is significantly high due to the large number of cell walls, frequent wall-to-wall contacts, and large deformations during loading. To address this, a symmetrical FE model was modelled and simulated to predict the crushing behaviour of a Nomex honeycomb under quasi-static axial compression, significantly reducing computational demand. The FE model’s force-displacement response, crushing load (13.3 N), absorbed energy (69.6 mJ), and fold formation (9 folds) showed good agreement with experimental tests, confirming its reliability as a design tool. Beyond structural validation, this research demonstrates the potential of flexible honeycomb structures in aerospace applications, where their lightweight, energy-absorbing, and adaptive characteristics make them ideal for impact resistance, crashworthiness, and morphing components. By enabling efficient modelling and sustainable design, the study supports the advancement of aerospace structures that enhance safety, minimize resource consumption, and contribute to both wealth preservation and the protection of human life.