Investigation of the mechanical properties of polyurethane foam-filled FDM-printed honeycomb core sandwich composites for aircraft

Abstract Sandwich composites are widely used in aerospace materials thanks to their low weight and high strength properties. The purpose of this study is to observe the effects of polyurethane foam filling on honeycomb core structures produced by additive manufacturing in terms of mechanical strength and moisture absorption properties. Within the scope of the study, honeycomb structures were produced by a 3D printer using polylactic acid (PLA) filament. Then, the honeycomb core was filled with polyurethane foam, which is supplied in liquid form. After the core material was given its final form, it was combined with an epoxy and carbon fibre facesheet material using the vacuum infusion technique. After the sandwich composite production was completed, in-plane compression, three-point bending, shear, and moisture absorption tests were applied. The polyurethane foam filling greatly increased the mechanical strength, but slightly more moisture absorption occurred in this structure compared to a hollow honeycomb structure.