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<p>The increasing need for structural materials that combine low weight with high mechanical performance has driven significant progress in modern protective systems. Additive Manufacturing (AM) has emerged as a powerful method for producing intricate cellular structures with customizable mechanical behaviour. Despite this, the application of AM-fabricated honeycomb cores in ballistic protection remains relatively underexplored. In this work, the impact performance of sandwich panels containing AM-produced honeycomb cores is investigated under hemispherical and conical projectile loading. Three core topologies such as reentrant, star-reentrant and octagonal were manufactured from AlSi10Mg using selective laser melting and assembled between two 1-mm-thick SS316 face sheets. Projectile speeds were varied between 200 and 270&#xa0;m/s. Complementary ballistic simulations were performed in ABAQUS/Explicit to replicate the experimental conditions. The simulated responses closely matched the tested specimens in terms of deformation patterns, damage evolution, and residual velocity trends. Among the configurations, the octagonal core provided the most effective energy absorption, offering 8.3% and 6.9% improvements over the reentrant and star-reentrant designs, respectively. Hemispherical projectiles also demanded 12.4% more energy to perforate the panels than their conical counterparts. Overall, the octagonal-core panels demonstrated enhanced ballistic resistance 10.5% higher than reentrant and 4.2% greater than star-reentrant specimens.</p>

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Impact resistance of additively manufactured honeycomb-cored sandwich panels against high-velocity projectiles: a comparative experimental and numerical study

  • 期刊论文

  • 发表日期：

    2026年5月4日

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  • Ahsan ul haq,
  • Suresh Kumar Reddy Narala,
  • Mohammed Farhan

摘要

The increasing need for structural materials that combine low weight with high mechanical performance has driven significant progress in modern protective systems. Additive Manufacturing (AM) has emerged as a powerful method for producing intricate cellular structures with customizable mechanical behaviour. Despite this, the application of AM-fabricated honeycomb cores in ballistic protection remains relatively underexplored. In this work, the impact performance of sandwich panels containing AM-produced honeycomb cores is investigated under hemispherical and conical projectile loading. Three core topologies such as reentrant, star-reentrant and octagonal were manufactured from AlSi10Mg using selective laser melting and assembled between two 1-mm-thick SS316 face sheets. Projectile speeds were varied between 200 and 270 m/s. Complementary ballistic simulations were performed in ABAQUS/Explicit to replicate the experimental conditions. The simulated responses closely matched the tested specimens in terms of deformation patterns, damage evolution, and residual velocity trends. Among the configurations, the octagonal core provided the most effective energy absorption, offering 8.3% and 6.9% improvements over the reentrant and star-reentrant designs, respectively. Hemispherical projectiles also demanded 12.4% more energy to perforate the panels than their conical counterparts. Overall, the octagonal-core panels demonstrated enhanced ballistic resistance 10.5% higher than reentrant and 4.2% greater than star-reentrant specimens.