Sandwich Panel Core Production Using Different Approaches in Additive Manufacturing: A Literature Review

Abstract

Sandwich panels are widely used across the aerospace, automotive, maritime, and construction industries due to their superior strength-to-weight ratio and energy-absorption capabilities. This review examines the production of sandwich panel cores, with particular emphasis on honeycomb structures, and evaluates the potential of additive manufacturing (AM) as an alternative to conventional fabrication methods. The study adopts a comprehensive literature review approach, analyzing traditional manufacturing techniques such as expansion and corrugation methods alongside emerging AM technologies, including fused deposition modeling (FDM), powder bed fusion, and direct ink writing. The findings indicate that while conventional methods remain effective, they are often constrained by design limitations, multi-step processes, and greater production complexity. In contrast, AM enables layer-by-layer fabrication directly from digital models, allowing greater design flexibility, reduced material waste, and the ability to produce complex geometries with comparable or enhanced mechanical performance. Furthermore, integrating advanced materials, such as carbon fiber-reinforced polymers, and applying simulation tools, such as finite element analysis, contribute to improved structural optimization. However, challenges related to material sustainability, scalability, and environmental impact remain significant. Overall, additive manufacturing offers a promising pathway to advance sandwich panel core production, particularly through design optimization, reduced production time, and enhanced performance, though further research is needed to address sustainability and large-scale implementation.