A New FE Modelling Approach to Simulate the Inter‐Layer Adherence in Hybrid Sandwich Structures Achievable by Additive Manufacturing

Numerically predicting the mechanical behavior of additively manufactured sandwich structures, particularly those produced through filament extrusion, poses a significant challenge. Existing collapse mechanisms, including interlayer debonding, lack comprehensive numerical formulation. This paper presents an improved finite element (FE) modeling approach for filament‐based additive processes. Utilizing the cohesive zone model (CZM), it incorporates a cohesive‐type contact to simulate critical layer interactions, such as the core‐face sheet interface. Validation against a literature‐referenced composite sandwich structure with designed for additive manufacturing honeycomb core demonstrates good agreement between the proposed numerical approach and experimental test data in compression and bending.