In recent years, sandwich structures have gained considerable attention in the fields of structural protection and energy absorption due to their lightweight and high-strength characteristics, holding great research significance. Traditional pyramid sandwich structures exhibit poor mechanical performance and energy absorption capability under axial loads. Therefore, this paper proposes three new three-dimensional double-layer pyramid sandwich structures, namely the type I double-layer symmetrical pyramid (TDSP I) structure, the type II double-layer symmetrical pyramid (TDSP II) structure, and the Type III double-layer symmetrical pyramid (TDSP III) structure. TDSP I introduces a double-layer pyramid unit based on the conventional single-layer pyramid sandwich structure. TDSP II further incorporates vertical struts on the basis of TDSP I, while TDSP III integrates reinforcing ribs in addition to the vertical struts. In terms of materials, carbon fiber is employed for the upper and lower face sheets, whereas 316L stainless steel is used for the core. The combination of these two materials enables the structure to maintain its lightweight characteristics while achieving enhanced structural stability and improved energy absorption performance; The study analyzes the force-displacement curves of these structures and provides a comprehensive comparison based on their deformation mechanisms and energy absorption capabilities. The research found that the specific energy absorption (SEA) of the TDSP III structure is 2.16 times that of the TDSP I structure and 1.58 times that of the TDSP II structure. Additionally, the paper explores the impact of different structural parameters on the energy absorption performance of the TDSP III structure. The results show that parameters such as the inclination angle of the support legs, leg thickness, and the lay-up angle of the carbon fiber panels significantly affect the overall energy absorption performance, allowing for directional regulation of energy absorption characteristics. In conclusion, the proposed double-layer symmetrical pyramid sandwich structure demonstrates promising engineering application prospects and research potential in structural protection and lightweight, high-efficiency energy absorption.
LiWZhangZZhangK, et al.High strength and damage tolerance in lightweight 3D-architectured ceramic/polymer composites with varied periodical topology. Addit Manuf2025; 97: 104605.
2.
LiuXCaiHSunY, et al.Spray-based 3D printed foam concrete: cooperative optimization for lightweight and high-strength performance. Constr Build Mater2024; 444: 137636.
3.
ZuoXYuJTangW, et al.Implosion collapse of externally pressurized steel/CFRP/titanium cylindrical shells with a hybrid sandwich thin-walled structure. Thin-Walled Struct2025; 210: 112988.
4.
Guerra SilvaRMorales PavezG. Flexural characteristics of additively manufactured continuous fiber-reinforced honeycomb sandwich structures. Composites Part C: Open Access2025; 16: 100563.
5.
FanMZengTWuR, et al.Bending behaviors of 3D printed sandwich structures with functionally graded porous lattice cores. Thin-Walled Struct2025; 206: 112655.
6.
ShiSWangGHuC, et al.Impact response of carbon fiber/aluminum honeycomb sandwich structures under multiple low-velocity loads. Compos Sci Technol2025; 261: 111027.
7.
HuJYaoSHuangX. Topological design of sandwich structures filling with poroelastic materials for sound insulation. Finite Elem Anal Des2022; 199: 103650.
8.
SongZSuLYuanM, et al.Self-cleaning, energy-saving aerogel composites possessed sandwich structure: improving indoor comfort with excellent thermal insulation and acoustic performance. Energy Build2024; 310: 114098.
9.
MallekHMellouliHAllouchM, et al.Energy absorption of 3D-printed PETG and PETG/CF sandwich structures with cellular cores subjected to low-velocity impact: experimental and numerical analysis. Eng Struct2025; 327: 119653.
10.
NovakNBorovinšekMAl-KetanO, et al.Impact and blast resistance of uniform and graded sandwich panels with TPMS cellular structures. Compos Struct2022; 300: 116174.
11.
TewariKPanditMKMahapatraMM, et al.Honeycomb-spiderweb-inspired self-similar hybrid cellular structures for impact applications. Def Technol2025; 43: 182–200.
12.
TarkashvandADaneshjouKGolmohammadiA. FG and viscoelastic models combination for vibroacoustic modeling of sandwich structures made of open and closed cell foam materials. Compos Struct2021; 259: 113438.
13.
SuMMaQZhangA, et al.Mechanical properties of sandwich structures with different webs enhanced by filling polyurethane foam and encasing rectangular tube. Mater Today Commun2024; 40: 110058.
14.
NajafiMEslami-FarsaniR. Design and characterization of a multilayered hybrid cored-sandwich panel stiffened by thin-walled lattice structure. Thin-Walled Struct2021; 161: 107514.
15.
LuoYFanH. Energy absorbing ability of rectangular self-similar multi-cell sandwich-walled tubular structures. Thin-Walled Struct2018; 124: 88–97.
16.
ZhaoJCuiZWangS, et al.Flexural response of additively manufactured honeycomb sandwich structures with continuous density-gradient variations. Thin-Walled Struct2024; 197: 111642.
17.
KhanAUSadhyaSBharath KumarA, et al.Investigation on dual wire TIG arc additive manufacturing of IN625 and SS316L FGM for continuous gradient and sandwich structures. Thin-Walled Struct2024; 200: 111881.
18.
QinYXiongCZhuX, et al.Failure mechanism and impact resistance of a novel all-composite double-corrugated sandwich plate under low-velocity impact. Case Stud Constr Mater2024; 20: e02724.
19.
DongWPanHSunY, et al.The sandwich-structured advanced high strength steel to resist the liquid metal embrittlement. J Mater Res Technol2023; 25: 3167–3176.
20.
PatelMPatelSAhmadS. Blast analysis of efficient honeycomb sandwich structures with CFRP/steel FML skins. Int J Impact Eng2023; 178: 104609.
21.
UmHJRhoHJJeonNH, et al.Mechanical performance of novel curved sandwich structures featuring 3D printed continuous carbon fiber/polyamide 6 composite corrugated core with rail interlocking. Compos B Eng2025; 295: 112222.
22.
LiuYZhouHYinC, et al.Experimental investigation on the residual bending capacity of carbon fiber corrugated sandwich structures under the repeated impact. Thin-Walled Struct2024; 199: 111754.
23.
ChenYJinZKangW, et al.3D printed bio-inspired self-similar carbon fiber reinforced composite sandwich structures for energy absorption. Compos Sci Technol2024; 248: 110453.
24.
WangZHongBXianG, et al.Quasi-static and low-velocity impact behaviors of steel-aluminum foam sandwich beams. Elsevier2024; 64: 106549.
25.
NsengiyumvaWZhongSLinJ, et al.Advances, limitations and prospects of nondestructive testing and evaluation of thick composites and sandwich structures: a state-of-the-art review. Compos Struct2021; 256: 112951.
26.
EvansKE. Auxetic polymers: a new range of materials. Endeavour1991; 15(4): 170–174.
27.
HanZWeiK. Multi-material topology optimization and additive manufacturing for metamaterials incorporating double negative indexes of Poisson’s ratio and thermal expansion. Addit Manuf2022; 54: 102742.
28.
CartaGBrunMBaldiA. Design of a porous material with isotropic negative Poisson’s ratio. Mech Mater2016; 97: 67–75.
29.
WangSZengYWangC, et al.Negative Poisson’s ratio structural cellulose aerogel with excellent impact resistance. Chem Eng J2025; 507: 160492.
30.
LonglongLLiangG. Research on the optimization and preparation of negative Poisson’s ratio structure of quartz glass. Mater Lett2025; 384: 138105.
31.
LinWWangYDavidsonBD. Negative Poisson’s ratio can enhance stability of layered composite structures. Thin-Walled Struct2024; 205: 112409.
32.
LinHBLiuHT. Mechanical properties and band gap characteristics of flexible skin based on multi-concave angle honeycomb. Mater Today Commun2023; 35: 106113.
33.
ChenZLiJWuB, et al.Enhanced mechanical properties of re-entrant auxetic honeycomb with self-similar inclusion. Compos Struct2024; 331: 117921.
34.
HuangWLinJJiangM, et al.Rapid prediction and tailoring on compressive behavior of origami-inspired hierarchical structure. Addit Manuf2025; 100: 104686.
35.
QiJLiCTieY, et al.Energy absorption characteristics of origami-inspired honeycomb sandwich structures under low-velocity impact loading. Mater Des2021; 207: 109837.
36.
ZhangDQinAKShenS, et al.Energy absorption analysis of origami structures based on small number of samples using conditional GAN. Thin-Walled Struct2023; 188: 110772.
37.
DengYZengXWangY, et al.Research on the low-velocity impact performance of composite sandwich structure with curved-crease origami foldcore. Thin-Walled Struct2022; 174: 109106.
38.
HassaniFJavanbakhtZMalekS. Large deformation behavior and energy absorption of rotating square auxetics. Compos B Eng2024; 283: 111596.
39.
XuWZhangLZhangB, et al.Crushing behavior of contact-aided AlSi10Mg sandwich structure based on chiral mechanical metamaterials. Int J Mech Sci2023; 260: 108636.
40.
ZhangJXieYLiZ, et al.Comparison of out-of-plane compression performance of cellular structures with different configuration: Hexagon, re-entrant, chirality. Elsevier2025; 73: 108396.
BianZGongYSunZ, et al.Design and energy absorption characteristics of a novel honeycomb with embedded chiral structures. Compos Struct2024; 333: 117944.
43.
LuoYMHeCTaoZ, et al.A surface-wave seismic metamaterial filled with auxetic foam. Int J Mech Sci2024; 262: 108715.
44.
UstaFTürkmenHSScarpaF. Low-velocity impact resistance of composite sandwich panels with various types of auxetic and non-auxetic core structures. Thin-Walled Struct2021; 163: 107738.
45.
YuYFuTWangS, et al.Dynamic response of novel sandwich structures with 3D sinusoid-parallel-hybrid honeycomb auxetic cores: the cores based on negative Poisson’s ratio of elastic jump. Eur J Mech Solid2025; 109: 105449.
46.
LiuHLiD. Study on the energy absorption effect and impact resistance of a composite sandwich panel with carbon fiber reinforced re-entrant hexagonal honeycomb core with negative Poisson’s ratio. Eur J Mech Solid2025; 109: 105447.
47.
ZhangYCaiDPengJ, et al.On low-velocity impact behavior of sandwich composites with negative Poisson’s ratio lattice cores. Compos Struct2022; 299: 116078.
48.
ZhouYJiangDWangL, et al.Cushioning performance of origami negative Poisson’s ratio honeycomb steel structure. Thin-Walled Struct2024; 204: 112284.
49.
LiXLiuPChengH, et al.Experimental and numerical analysis of low-velocity impact damage of CFRP laminates with negative Poisson ratio (NPR) rubber protective layer. Thin-Walled Struct2023; 191: 111066.
50.
EpastoGRizzoDLandolfiL, et al.Design of monomaterial sandwich structures made with foam additive manufacturing. J Manuf Process2024; 121: 323–332.
51.
PierreJVervilleMChenierG, et al.Non-planar material-extrusion additive manufacturing of multifunctional sandwich structures using carbon-reinforced polyetheretherketone (PEEK). Addit Manuf2024; 84: 104124.
52.
WangZWangYHeJ, et al.Additive manufacturing of continuous fiber-reinforced polymer composite sandwich structures with multiscale cellular cores. Chin J Mech Eng: Addit Manuf Front2023; 2(3): 100088.
53.
XuTHuangJCuiY, et al.Exploring a novel panel-core connection method of large size lattice sandwich structure based on wire arc additive manufacturing. Mater Des2021; 212: 110223.
54.
HanYSuSXYangL, et al.The investigation on the bending fatigue properties of Ti–6Al–4V lattice sandwich structures fabricated EB-PBF. J Mater Res Technol2024; 33: 3163–3173.
55.
ZhaiZWangSYangG, et al.Novel sandwich structures with double-row and crossed pyramidal lattice cores: design, fabrication and bending behavior. Eng Fail Anal2025; 170: 109267.
56.
XuTJingCMaoH, et al.Parallel multi arc directed energy deposition: new way to achieve efficient manufacturing of large-size lattice sandwich structure. Addit Manuf2024; 90: 104322.
57.
ZhangXXuCLiW, et al.Study on the bending and shear properties of quasi-honeycomb sandwich structures considering the variable-density core design. Compos Struct2023; 324: 117517.
58.
LiZJDaiHLYaoY, et al.Thermo-mechanical modeling of lattice-core sandwich panels in powder bed fusion. Int J Mech Sci2024; 273: 109243.
59.
LiKFangJZhanJ, et al.A critical review of biomimetic structures via laser powder bed fusion: toward multi-functional application. J Manuf Process2024; 131: 2443–2472.
60.
MengLLanXZhaoJ, et al.Failure analysis of bio-inspired corrugated sandwich structures fabricated by laser powder bed fusion under three-point bending. Compos Struct2021; 263: 113724.
61.
XieZZhouYWangX, et al.Interfacial characterization and bonding mechanism of W/ODS-316 L steel multi-material structure fabricated by laser powder bed fusion. Mater Char2024; 216: 114242.
62.
ZhuJChenJAnZ, et al.Photocuring 3D printable self-healing polymers. Eur Polym J2023; 199: 112471.
63.
GhoshMD'SouzaNAXuY, et al.Scalability in SLA lattice through lattice orientation and hybrid frame and plate architectures. J Mater Res Technol2025; 35: 645–659.
64.
YanCHaoLHusseinA, et al.Advanced lightweight 316L stainless steel cellular lattice structures fabricated via selective laser melting. Mater Des2014; 55: 533–541.
65.
LiXQuPKongH, et al.Enhanced mechanical properties of sandwich panels via integrated 3D printing of continuous fiber face sheet and TPMS core. Thin-Walled Struct2024; 204: 112312.
66.
YinDZhengJXiongC, et al.Experimental and numerical studies of perforated CFRP laminates under quasi-static tensile load. IOP Conf Ser Mater Sci Eng2021; 1040(1): 012011.
67.
UmbrelloDM’SaoubiROuteiroJC. The influence of Johnson–Cook material constants on finite element simulation of machining of AISI 316L steel. Int J Mach Tool Manufact2007; 47(3-4): 462–470.
68.
LiQMMagkiriadisIHarriganJJ. Compressive strain at the onset of densification of cellular solids. J Cell Plast2006; 42(5): 371–392.
69.
YinHZhangWZhuL, et al.Review on lattice structures for energy absorption properties. Compos Struct2023; 304: 116397.
70.
SongSXiongCYinJ. Mechanical performance of reinforced hybrid periodic-multicell thin-walled structures in sandwich applications: a review. Thin-Walled Struct2025; 208: 112832.
71.
LuoHGaoQZhouJ, et al.Hybrid honeycombs with re-entrant auxetic and face-centered cubic cells: design and mechanical characteristics. Eng Struct2025; 328: 119731.
72.
SharmaDHiremathSS. Bio-inspired repeatable lattice structures for energy absorption: experimental and finite element study. Compos Struct2022; 283: 115102.
