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<p>Honeycomb structures are widely used in industry due to their low density and high energy absorption capacity. However, due to their load-bearing limitations, researchers are constantly seeking to design improved structures. In this study, a novel gradient honeycomb structure inspired by sunflowers is introduced, where the size of the hexagonal cells gradually decreases along the radius. Also, the performance of polyurethane foam as a filler in the honeycomb structure is investigated. In this research, specimens were made of PLA + using a 3D printer, and after injecting foam into the space between the cells, the specimens were subjected to quasi-static and impact loading. The results showed that in quasi-static loading, the sunflower-inspired honeycomb in empty and foam-filled conditions absorbed 219 and 336&#xa0;Joules of energy, respectively, and its SEA was 2.67 and 3.05&#xa0;J/g, respectively. These values indicate a 13 and 14% increase in EA and a 27 and 22% increase in SEA compared to the conventional honeycomb. In impact loading, the sunflower-inspired honeycomb in empty and foam-filled conditions absorbed 55.1 and 63.2&#xa0;Joules of energy, respectively, and its CFE was 90 and 82%, respectively. These values indicate an 11 and 8% increase in EA and a 45 and 30% increase in CFE compared to the conventional honeycomb. The results show that the gradient design of honeycomb cells inspired by sunflowers and the injection of PU foam into the space of the honeycomb structure improves the crashworthiness and SEA of these structures promisingly and can be used as an energy absorber in the core of sandwich panels, airfoils, and car bumpers.</p> Graphical abstract <p></p>

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Enhanced crashworthiness and energy absorption properties of honeycomb structures with a novel sunflower-inspired design

  • 期刊论文

  • 发表日期：

    2025年5月20日

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  • Reza Sarkhosh

摘要

Honeycomb structures are widely used in industry due to their low density and high energy absorption capacity. However, due to their load-bearing limitations, researchers are constantly seeking to design improved structures. In this study, a novel gradient honeycomb structure inspired by sunflowers is introduced, where the size of the hexagonal cells gradually decreases along the radius. Also, the performance of polyurethane foam as a filler in the honeycomb structure is investigated. In this research, specimens were made of PLA + using a 3D printer, and after injecting foam into the space between the cells, the specimens were subjected to quasi-static and impact loading. The results showed that in quasi-static loading, the sunflower-inspired honeycomb in empty and foam-filled conditions absorbed 219 and 336 Joules of energy, respectively, and its SEA was 2.67 and 3.05 J/g, respectively. These values indicate a 13 and 14% increase in EA and a 27 and 22% increase in SEA compared to the conventional honeycomb. In impact loading, the sunflower-inspired honeycomb in empty and foam-filled conditions absorbed 55.1 and 63.2 Joules of energy, respectively, and its CFE was 90 and 82%, respectively. These values indicate an 11 and 8% increase in EA and a 45 and 30% increase in CFE compared to the conventional honeycomb. The results show that the gradient design of honeycomb cells inspired by sunflowers and the injection of PU foam into the space of the honeycomb structure improves the crashworthiness and SEA of these structures promisingly and can be used as an energy absorber in the core of sandwich panels, airfoils, and car bumpers.

Graphical abstract