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<p>This study reports the design, fabrication, and experimental investigation of 3D-printed honeycomb structures subjected to drop-weight impact testing. Hexagonal honeycomb structures were designed using CAD software and fabricated using Fused Deposition Modeling (FDM) with PLA (Polylactic Acid) material. The primary objectives were to analyze energy absorption capacity, deformation characteristics, and failure mechanisms under controlled dynamic impact loading. Drop-weight impact tests were conducted at three distinct heights (1.0&#xa0;m, 1.5&#xa0;m, and 2.0&#xa0;m), with a striker mass of 63.6&#xa0;kg, systematically evaluating different impact energy levels. Force-displacement behavior and post-impact failure modes were documented to assess structural response. Results demonstrated that the honeycomb structure absorbed 624&#xa0;J, 936&#xa0;J, and 1248&#xa0;J of energy at 1.0&#xa0;m, 1.5&#xa0;m, and 2.0&#xa0;m drop heights, respectively, with corresponding displacements of 28–32&#xa0;mm, 33–39&#xa0;mm, and 45–50&#xa0;mm. Specific energy absorption (SEA) values increased from 9.81&#xa0;J/kg to 19.62&#xa0;J/kg with increasing impact height. Progressive cell wall buckling and densification were identified as primary deformation mechanisms. This work contributes to understanding the performance of polymer-based cellular structures under dynamic impact loading and provides a foundation for optimization in crashworthy applications in aerospace, automotive, and protective equipment sectors.</p>

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Design and Fabrication of 3D Printed Honeycomb Structure Subjected to Drop Weight Impact Test

  • 期刊论文

  • 发表日期：

    2026年5月8日

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  • E Devaraj,
  • Chandrashekhar Bendigeri,
  • R Manoj

摘要

This study reports the design, fabrication, and experimental investigation of 3D-printed honeycomb structures subjected to drop-weight impact testing. Hexagonal honeycomb structures were designed using CAD software and fabricated using Fused Deposition Modeling (FDM) with PLA (Polylactic Acid) material. The primary objectives were to analyze energy absorption capacity, deformation characteristics, and failure mechanisms under controlled dynamic impact loading. Drop-weight impact tests were conducted at three distinct heights (1.0 m, 1.5 m, and 2.0 m), with a striker mass of 63.6 kg, systematically evaluating different impact energy levels. Force-displacement behavior and post-impact failure modes were documented to assess structural response. Results demonstrated that the honeycomb structure absorbed 624 J, 936 J, and 1248 J of energy at 1.0 m, 1.5 m, and 2.0 m drop heights, respectively, with corresponding displacements of 28–32 mm, 33–39 mm, and 45–50 mm. Specific energy absorption (SEA) values increased from 9.81 J/kg to 19.62 J/kg with increasing impact height. Progressive cell wall buckling and densification were identified as primary deformation mechanisms. This work contributes to understanding the performance of polymer-based cellular structures under dynamic impact loading and provides a foundation for optimization in crashworthy applications in aerospace, automotive, and protective equipment sectors.