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The purpose of this review paper is to provide a review of the most recent advances in the field of manufacturing composite sandwich panels along with their advantages and limitations. The other purpose of this paper is to familiarize the researchers with the available developments in manufacturing sandwich structures.

The most recent research articles in the field of manufacturing various composite sandwich structures were reviewed. The review process started by categorizing the available sandwich manufacturing techniques into nine main categories according to the method of production and the equipment used. The review is followed by outlining some automatic production concepts toward composite sandwich automated manufacturing. A brief summary of the sandwich manufacturing techniques is given at the end of this article, with recommendations for future work.

It has been found that several composite sandwich manufacturing techniques were proposed in the literature. The diversity of the manufacturing techniques arises from the variety of the materials as well as the configurations of the final product. Additive manufacturing techniques represent the most recent trend in composite sandwich manufacturing.

This work is valuable for all researchers in the field of composite sandwich structures to keep up with the most recent advancements in this field. Furthermore, this review paper can be considered as a guideline for researchers who are intended to perform further research on composite sandwich structures.

Gives a bibliographical review of the finite element analyses of sandwich structures from the theoretical as well as practical points of view. Both isotropic and composite materials are considered. Topics include: material and mechanical properties of sandwich structures; vibration, dynamic response and impact problems; heat transfer and thermomechanical responses; contact problems; fracture mechanics, fatigue and damage; stability problems; special finite elements developed for the analysis of sandwich structures; analysis of sandwich beams, plates, panels and shells; specific applications in various fields of engineering; other topics. The analysis of cellular solids is also included. The bibliography at the end of this paper contains 655 references to papers, conference proceedings and theses/dissertations dealing with presented subjects that were published between 1980 and 2001.

The aim of this study is to perform a comparative study on sandwich structures with several types of three-dimensional (3D) reticulate cellular structural core designs for their low-energy impact absorption abilities using powder bed additive manufacturing methods. 3D reticulate cellular structures possess promising potentials in various applications with sandwich structure designs. One of the properties critical to the sandwich structures in applications, such as aerospace and automobile components, is the low-energy impact performance.

Sandwich samples of various designs, including re-entrant auxetic, rhombic, hexagonal and octahedral, were designed and fabricated via selective laser sintering (SLS) process using nylon 12 as material. Low-energy drop weight test was performed to evaluate the energy absorption of various designs. Tensile coupons were also produced using the same process to provide baseline material properties. The manufacturing issues such as geometrical accuracy and anisotropy effect as well as their effects on the performance of the structures were discussed.

In general, 3D reticulate cellular structures made by SLS process exhibit significantly different characteristics under low-energy drop weight impact compared to the regular extruded honeycomb sandwich panels. A hexagonal sandwich panel exhibits the largest compliance with the smallest energy absorption ability, and an octahedral sandwich panel exhibits high stiffness as well as good impact protection ability. Through a proper geometrical design, the re-entrant auxetic sandwich panels could achieve a combination of high energy absorption and low response force, making it especially attractive for low-impact protection applications.

There has been little work on the comparative study of the energy absorption of various 3D reticulate cellular structures to date. This work demonstrates the potential of 3D reticulate cellular structures as sandwich cores for different purposes. This work also demonstrates the possibility of controlling the performance of this type of sandwich structures via geometrical and process design of the cellular cores with powder bed additive manufacturing systems.

This study aims to understand how the facesheet size, orientation and core size influence the analytical failure mechanism mode of glass fibre reinforced polymer (GFRP)/polyvinyl chloride (PVC) sandwich structures subjected to three-point bending. The purpose of this study was to develop failure-mode map of GFRP/PVC sandwich structures. Sandwich structures with different facesheet and core thicknesses were used to develop the failure map.

The sandwich structure and facesheet were fabricated using a vacuum-assisted resin infusion method with core sizes of 10, 15 and 20 mm and facesheet thicknesses of 1.5 and 3 mm and were arranged in three different orientations: angle-ply, cross-ply and quasi-isotropic. The key failure modes that occur in sandwich structures were used to predict possible failures in the developed material. Analytical equations were used in MATLAB for each observed failure mode. The probable failure modes, namely, face yielding, core shear and indentation equations, were used to construct the failure maps and were compared with the experimental data.

The boundary of the two failure modes shifts with changes in the facesheet and core thicknesses. The theoretical stiffness of sandwich panels was higher than the experimental stiffness. Based on strength-to-weight ratio, specimens E10-4, A15-8 and E20-8 exhibited the best optimum values owing to their shorter distance to the boundary lines.

In this study, a failure map was used to predict the possible failure modes for different GFRP facesheet orientations and thicknesses and PVC core thickness sandwich structures. Little is known about the prediction of the failure modes of unidirectional GFRP arranged in different orientations and thicknesses and PVC core thicknesses for sandwich structures. Few studies have used failure mode maps with unidirectional GFRP oriented in angle-ply, cross-ply and quasi-isotropic directions as a facesheet for sandwich structures compared to bidirectional mats. This study can serve as a guide for the correct selection of materials during the design process of sandwich structures.

This study aims to characterize a novel glass/epoxy architecture sandwich structure for electronic boards. Understanding the thermo-mechanical behavior of these composites is important because it is possible to pre-determine whether defined “internal” thick laminates will be suitable for embedding components in the direction of the axis “z,” i.e. this method of manufacturing multilayer laminates can be used for incoming miniaturization in electronics.

Laminates with a low glass transition temperature (Tg) and high Tg with E-glass type were treated, tested and compared. Testing samples were manufactured by nonstandard two steps unidirectional lamination as a multilayer structure based on prepreg layers and as “a sandwich structure” to explore its effect on thermo-mechanical properties. The proposed tested method determines the time and temperature-dependent viscoelastic properties of the board by using dynamic mechanical analysis, thermo-mechanical analysis and three-point bend tests.

This testing method was chosen because the main property that promotes sandwich structure is their high stiffness. Glass/epoxy stiff and thermal stabile sandwich structure prepared by nonstandard two-stage lamination is proper for embedding components and the next miniaturization in electronics.

Compared with by-default applied glass-reinforced homogenous laminates, novel architecture sandwich structure is attractive because of a combination of strength, stiffness and all while maintaining the miniaturization requirement and multifunctional application in electronics.

Defects can be caused by a number of factors, such as maintenance damage, ground handling and foreign objects thrown up from runways during an in-service use of composite aerospace structures. Sandwich structures are capable of absorbing large amounts of energy under impact loads, resulting in high structural crashworthiness. This situation is one of the many reasons why sandwich structures are extensively used in many aerospace applications nowadays. Their non-destructive inspection is often more complex. Hence, the choice of a suitable non-destructive testing (NDT) method can play a key role in successful damage detection. The paper aims to discuss these issues.

A comparison of detection capabilities of selected C-scan NDT methods applicable for inspections of sandwich structures was performed using water-squirt, air-coupled and pitch-catch (PC) ultrasonic techniques, supplemented by laser shearography (LS).

Test results showed that the water-squirt and PC techniques are the most suitable methods for core damage evaluation. Meanwhile, the air-coupled method showed lower sensitivity for the detection of several artificial defects and impact damage in honeycomb sandwiches when unfocussed transducers were used. LS can detect most of the defects in the panels, but it has lower sensitivity and resolution for honeycomb core-type sandwiches.

This study quantitatively compared the damage size indication capabilities of sandwich structures by using various NDT techniques. Results of the realised tests can be used for successful selection of a suitable NDT method. Combinations of the presented methods revealed most defects.

Auxetic sandwich structures are gaining attention because of the negative Poisson’s ratio effect offered by these structures. Re-entrant core was one configuration of the auxetic structures. There is a growing concern about the design and behavior of re-entrant cores in aerospace, marine and protection applications. Several researchers proposed various designs of re-entrant core sandwiches with various materials. The purpose of this study is to review the most recent advances in re-entrant core sandwich structures. This review serves as a guide for researchers conducting further research in this wide field of study.

The re-entrant core sandwich structures were reviewed in terms of their design improvements, impact and quasi-static crushing responses. Several design improvements were reviewed including 2D cell, 3D cell, gradient, hierarchical and hybrid configurations. Some common applications of the re-entrant core sandwiches were given at the end of this paper with suggestions for future developments in this field.

Generally, the re-entrant configuration showed improved energy absorption and impact response among auxetic structures. The main manufacturing method for re-entrant core manufacturing was additive manufacturing. The negative Poisson’s ratio effect of the re-entrant core provided a wide area of research.

Generally, re-entrant cores were mentioned in the review articles as part of other auxetic structures. However, in this review, the focus was solely made on the re-entrant core sandwiches with their mechanics.

The purpose of this paper is to develop a general mathematical model for the evaluation of the bending and vibration responses of the skew sandwich composite plate using higher-order shear deformation theory. The sandwich structural components are highly preferable in modern engineering application because of their desirable structural advantages despite the manufacturing and analysis complexities. The present model is developed to solve the bending and vibration problem of the skew sandwich composite plate with adequate accuracy numerically in the absence of the experimental analysis.

The skew sandwich composite plate structure is modelled in the present analysis by considering laminated face sheet in conjunction with isotropic and/or orthotropic core numerically with the help of the higher-order mathematical model. Further, the responses are computed numerically with the help of in-house computer code developed in matrix laboratory (MATLAB) environment in conjunction with finite element (FE) steps. The system governing equations are derived via variational technique for the computation of the static and the frequency responses.

The skew sandwich composite plate is investigated using the higher-order kinematic model where the transverse displacement through the thickness is considered to be linear. The convergence and the validation study of the bending and the frequency values of the sandwich structure indicate the necessary accuracy. Further, the current model has been used to highlight the applicability of the higher-order kinematics for the evaluation of the sandwich structural responses (frequency and static deflections) for different design parameters.

In the present paper, the bending and the vibration responses of the skew sandwich composite plate are analysed numerically using the equivalent single-layer higher-order kinematic theory for the isotropic and the orthotropic core numerically with the help of isoparametric FE steps. Finally, it is understood that the present model is capable of solving the sandwich structural responses with less computation cost and adequate accuracy.

Sandwich construction with aluminium honeycomb cores bonded to faces with the adhesive films Redux 775, 775R and Bloomingdale FM‐47 is discussed. Drawings showing its applications to a series of components for various hypothetical aircraft arc included. Sandwich materials for supersonic aircraft of the types now entering production are reviewed, as well as the application techniques of the new Redux films. Some rules gathered from experience for the design of components with honeycomb cores, and solutions of special design problems with hypothetical wing panels, are treated. The paper then deals fairly fully with results from a programme of FFA investigations on this type of structure. The specimens discussed were bonded with Redux 775 and FM‐47 and consisted partly of tensile tests on cores, compressive tests on sandwich columns and shear tests on various sandwich webs. Design curves have been plotted in some cases. Further results are presented showing the influence of temperature on the shear strength of an aluminium alloy core and Redux 775 and FM‐47 films. Also a few creep results are given where the object of the tests has been to determine the optimum curing temperature and time for applying Redux 775 to yield minimum creep values. The room‐temperature results illustrate the excellent properties of honeycomb structures and the elevated‐temperature results indicate that bonded uninsulated aluminium sandwiches can be retained, even when the temperature due to kinetic heating approaches 70 deg. C. Finally, some remarks regarding future developments are made on various new ‘temperature‐resistant’ adhesives and on combinations of various materials for sandwich panels with external insulation, suitable for certain types of the next breed of supersonic aircraft.

Gives a bibliographical review of the finite element methods (FEMs) applied for the linear and nonlinear, static and dynamic analyses of basic structural elements from the theoretical as well as practical points of view. The range of applications of FEMs in this area is wide and cannot be presented in a single paper; therefore aims to give the reader an encyclopaedic view on the subject. The bibliography at the end of the paper contains 2,025 references to papers, conference proceedings and theses/dissertations dealing with the analysis of beams, columns, rods, bars, cables, discs, blades, shafts, membranes, plates and shells that were published in 1992‐1995.