Aerodynamic Design and Structural Evaluation of a TPMS-Core, Composite-Reinforced Nose Cone

This work presents the design rationale and multi-physics assessment of a nose cone that combines a low-drag Haackseries external profile with an additively manufactured triply periodic minimal surface (TPMS) lattice core and composite laminate skins. The selected LD-Haack (von Kármán) geometry targets reduced wave-drag in the transonic regime for slender finned vehicles, while the TPMS core enables high specific stiffness and tunable energy absorption relative to conventional foam or honeycomb cores. The structure is realized by 3D-printing a polymeric TPMS core and co-bonding (or secondary bonding) carbon- or glass-fiber reinforced polymer (CFRP/GFRP) skins to obtain a smooth aerodynamic surface and laminate tailoring for bending and buckling resistance. The evaluation methodology integrates (i) computational fluid dynamics (Mach 0.31.2) to quantify pressure distribution, drag coefficient, and flow features near the shoulder; (ii) finite-element analysis to assess global stiffness, local buckling, and failure modes (core shear, facesheet wrinkling, and delamination hotspots); and (iii) aero-thermal checks using stagnation-line heating correlations to bound surface temperature rise during flight. The analyses are organized in a design–test feedback loop to reduce modeling uncertainty and converge on a weight-efficient lay-up and core topology. Results indicate that the TPMS-core sandwich with composite skins can achieve a favorable stiffness-to-mass ratio while maintaining low external drag, with damage-tolerant failure modes and straightforward repair strategies (facesheet patching, localized core replacement). The workflow generalizes to fairings and small-vehicle nose cones, providing a scalable path from model-rocket scales to more demanding mission profiles.