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<p>A carbon fiber reinforced honeycomb core was designed and fabricated using the continuous 3D woven process, which has advantages including more automatic fabrication, more continuous inter-layer connection and wider design space compared to conventional processes such as tailor-folding. The weaving-stretch method employed in this carbon fiber 3D woven honeycomb (3DWH) preform was rarely reported in pertinent literatures. A finite element model is developed to explore mechanical and thermal stability behavior of the 3DWH cores, and an optimized process and geometric parameters are obtained by a parametric investigation. Simulation results are validated based on some standard tension and CTE tests. The final optimized 3DWH core has several excellent properties incorporating a low density of 0.12&#xa0;g/cm<sup>3</sup>, a low CTE of 1.192 × 10<sup>–6</sup>/K, a high out-of-plane compression strength of 10.89&#xa0;MPa, a high L-direction shear strength of 1.13&#xa0;MPa and a side length of 12.7&#xa0;mm, which indicates a great potential in lightweight and a high thermal dimensional stable structure.</p>

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Design and Fabrication of a Carbon Fiber Reinforced 3D Woven Honeycomb Core

  • 期刊论文

  • 发表日期：

    2026年2月14日

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  • Liping Zhu,
  • Cheng Yang,
  • Qian Zhao,
  • Weicheng Gao,
  • Pengfei Jiang,
  • Jing Feng,
  • Zicheng Jin

摘要

A carbon fiber reinforced honeycomb core was designed and fabricated using the continuous 3D woven process, which has advantages including more automatic fabrication, more continuous inter-layer connection and wider design space compared to conventional processes such as tailor-folding. The weaving-stretch method employed in this carbon fiber 3D woven honeycomb (3DWH) preform was rarely reported in pertinent literatures. A finite element model is developed to explore mechanical and thermal stability behavior of the 3DWH cores, and an optimized process and geometric parameters are obtained by a parametric investigation. Simulation results are validated based on some standard tension and CTE tests. The final optimized 3DWH core has several excellent properties incorporating a low density of 0.12 g/cm3, a low CTE of 1.192 × 10–6/K, a high out-of-plane compression strength of 10.89 MPa, a high L-direction shear strength of 1.13 MPa and a side length of 12.7 mm, which indicates a great potential in lightweight and a high thermal dimensional stable structure.