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<p>This study investigates the mechanical and thermal behavior of hexagonal honeycomb core sandwich structures fabricated through thermoplastic materials, i.e., Polyethylene Terephthalate Glycol (PETG) and Wood Poly lactic Acid (WPLA), using fused deposition modeling (FDM) technology. To enhance structural integrity and insulation capability, fly ash geopolymer composite (FAGC) was incorporated into the honeycomb cores between two 1.6&#xa0;mm face plates. A comprehensive mechanical characterization was conducted, including compression and flexural tests, to evaluate the effect of FAGC incorporation on the PETG and WPLA composite cores. Thermal characterization was also conducted to determine thermal conductivity, thermal diffusivity, and specific heat, for evaluating the heat transfer behavior. The results reveal that FAGC-filled cores provided almost double the compressive strength of unfilled PETG structures and improved WPLA’s compressive behavior. However, the inclusion of FAGC reduced flexural strength (~ 20% for PETG and ~ 54% for WPLA), due to poor interfacial adhesion between the thermoplastic matrix. This was validated through Finite Element Analysis (FEA) and Scanning Electron Microscopy (SEM). Meanwhile, FAGC reduced thermal conductivity and diffusivity while increasing specific heat, with PETG–FAGC composites showing the most effective insulation performance. Overall, the findings demonstrate that integrating fly ash-based fillers into thermoplastic honeycomb cores provides a cost-effective pathway to multifunctional materials, particularly suited for building and structural applications where compressive strength and thermal management are prioritized over bending resistance.</p>

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Experimental and Numerical Study on Fly Ash-Reinforced Core of 3D Printed PETG/Wood-PLA Honeycomb Sandwich Composites

  • 期刊论文

  • 发表日期：

    2026年3月7日

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  • Jasim Ahmed Chowdhury,
  • Tanvir Ahmed Fahim,
  • Suvojit Baidya,
  • Md. Shariful Islam,
  • Md. Abdul Hasib

摘要

This study investigates the mechanical and thermal behavior of hexagonal honeycomb core sandwich structures fabricated through thermoplastic materials, i.e., Polyethylene Terephthalate Glycol (PETG) and Wood Poly lactic Acid (WPLA), using fused deposition modeling (FDM) technology. To enhance structural integrity and insulation capability, fly ash geopolymer composite (FAGC) was incorporated into the honeycomb cores between two 1.6 mm face plates. A comprehensive mechanical characterization was conducted, including compression and flexural tests, to evaluate the effect of FAGC incorporation on the PETG and WPLA composite cores. Thermal characterization was also conducted to determine thermal conductivity, thermal diffusivity, and specific heat, for evaluating the heat transfer behavior. The results reveal that FAGC-filled cores provided almost double the compressive strength of unfilled PETG structures and improved WPLA’s compressive behavior. However, the inclusion of FAGC reduced flexural strength (~ 20% for PETG and ~ 54% for WPLA), due to poor interfacial adhesion between the thermoplastic matrix. This was validated through Finite Element Analysis (FEA) and Scanning Electron Microscopy (SEM). Meanwhile, FAGC reduced thermal conductivity and diffusivity while increasing specific heat, with PETG–FAGC composites showing the most effective insulation performance. Overall, the findings demonstrate that integrating fly ash-based fillers into thermoplastic honeycomb cores provides a cost-effective pathway to multifunctional materials, particularly suited for building and structural applications where compressive strength and thermal management are prioritized over bending resistance.