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The purpose of this paper is to present the studies to develop structural highly orthotropic panels. These types of panels provide the capabilities required for structural morphing. They are highly deformable in one given direction; and in the perpendicular direction, one must be compliant to sustain the internal loads per certification stiffness and strength requirements.

Neither classic orthotropic panels nor regular cellular solids Bloch wave theories are strictly applicable on their study. A combination of computational method, MATLAB-coded, to analyze stability and classic structural beam theory is studied. Then, non-linear finite element method models are developed for an aerospace control surface application; their results are compared with reported Bloch wave sequences on periodic cellular solid panels.

The stability along stiffer direction is a requirement to obtain a continuous deformation and plasticization sequence of the cell rows in the perpendicular direction. A sample panel is sized and 3D modeled, and then produced using additive layer manufacturing process to demonstrate the initial stages of a validation and verification campaign.

This paper provides a new method to mechanical characterize highly orthotropic panels.