Evaluation of Impact Performance via FEM Modelling and Experimental Testing of 3D-Printed Honeycomb Energy-Absorbing Crush-Type Structures

This study investigates the energy absorption capacity of large three-honeycomb cell cores of different geometrical configurations, focusing on the influence of the constructive parameters on their impact response. The analyzed sandwich structures were additively manufactured using Onyx (a nylon-based composite) for the core cells and integrated into an assembly consisting of 6060-aluminum face sheets and encapsulated within a 6060-aluminum tube. These configurations represent a realistic engineering solution for lightweight structures designed for energy absorption. The analyses were conducted for two impact energy levels, 20 J and 50 J, enabling the evaluation of the structural sensitivity to different dynamic loading conditions. The results indicate a significant reduction in peak force with an increasing number of cells along the height. Compared to the single-cell configuration, the peak force decreases by approximately 15% for the two-cell configuration and 22.5% for the three-cell configuration, corresponding to a reduction of roughly 9% between the two- and three-cell cases. These findings highlight the critical role of geometry in optimizing the impact performance of honeycomb structures and provide relevant insights for the design of additively manufactured energy-absorbing crush-type components in engineering applications.