Load-dependent optimization of honeycombs for sandwich components-new possibilities by using additive layer manufacturing

Due to their feasible geometric complexity, additive layer manufacturing (ALM) processes show a high potential for the production of lightweight components. Therefore, ALM processes enable the realization of bionic-designed components like honeycombs, which are optimized depending upon load and outer boundary conditions. This optimization is based on a closed-loop, three-steps methodology: At first, each honeycomb is conformed to the surface of the part. Secondly, the structure is optimized for lightweight design. It is possible to achieve a homogeneous stress distribution in the part by varying the wall thickness, honeycomb diameter and the amount of honeycombs, depending on the subjected stresses and strains. At last, the functional components like threads or bearing carriers are integrated directly into the honeycomb core. Using all these steps as an iterative process, it is possible to reduce the mass of sandwich components about 50 percent compared to conventional approaches.