Influence of Cell Size on the Mechanical Performance of Al‐Pla Sandwich Specimens Subjected to Three‐Point Bending

ABSTRACT In this paper, the authors analyze, based on the optimal ratio between strength and weight of the core in a sandwich panel, the performance of an Al‐PLA composite material subjected to three‐point bending. The studied panel consists of aluminum face sheets with a thickness of 0.5 mm, while the core is manufactured using FDM (Fused Deposition Modeling) 3D printing technology, employing polylactic acid (PLA). The study focuses on five specimens, all featuring a hexagonal honeycomb core structure, with the main variable being cell size, which directly influences core density. The primary objective of this research is to determine the most efficient core configuration that ensures an optimal balance between mechanical strength and structural weight. The study investigates how variations in hexagon size affect the panel's behavior under three‐point bending loads, considering the impact on mechanical performance and material efficiency. Furthermore, the research highlights the importance of using lightweight materials such as PLA and advanced 3D printing technologies to develop efficient and sustainable structures with reduced costs and superior mechanical properties.