Mechanical Performance of Novel 3D-Printed Symmetric Corrugated Hierarchical Honeycombs

Symmetric corrugated hierarchical honeycombs (SCHHs) are critical lightweight load-bearing structures, featuring distinctive topological architectures and excellent mechanical performance. However, they are prone to local buckling under out-of-plane compression and shear loading, which degrades their overall load-bearing capacity. To address this limitation, this work proposes an innovative dual-optimization strategy integrating cylindrical support structure introduction and nano-silica (SiO2) matrix modification to synergistically enhance the compressive and tribological properties of SCHHs. 3D-printed SCHHs and their reinforced variant (SCHH-AC) with embedded cylindrical supports were fabricated, and the effects of nano-SiO2 modification (0–9 wt.%) on the compressive performance and tribological behavior of the photopolymer resin matrix were systematically investigated. Experimental results demonstrate that the SCHH-AC-7% SiO2 configuration achieves optimal compressive performance. A critical SiO2 concentration threshold was identified: agglomeration at 9 wt.% induces severe mechanical degradation. Tribological tests confirm that SiO2 incorporation effectively reduces the resin matrix’s friction coefficient and wear rate, with the 7 wt.% concentration yielding the lowest wear rate. Additionally, geometric parametric analysis reveals that increasing the corrugation period number and amplitude further enhances SCHH’s compressive strength and energy absorption. This study establishes a theoretical and experimental foundation for the structural design and material modification of lightweight honeycombs, advancing their practical application in high-performance engineering fields demanding lightweight load-bearing and wear resistance.