This study presents the first assessment of sustainable aluminium sandwich panels with an arched-core geometry. The arches are constructed from recycled aluminium obtained from drink container cans and bonded to aluminium skins using a polymer system. Through statistical analysis, the research aims to investigate the influence of the adhesive system (castor-oil or epoxy), adhesive layer thickness (0.8 mm or 1.5 mm), and core arch configuration (aligned or alternated pattern) on the mechanical performance of the sandwich panels, evaluated through a three-point bending test. The Al-arched-core panels, with a support span of 150 mm and a width of 75 mm, achieve a maximum load of 500 N, equivalent to 51 kg per 150 × 75 mm2. Additionally, the panels exhibit a core shear modulus of up to 10 MPa, while the flexural modulus under pure bending is estimated to be approximately 7 GPa. The mechanical performance of the panels is further enhanced by utilising thicker adhesive layers. Employing alternated arches in the core improves the distribution of flexural stress along the panel. These Al-arched-core panels demonstrate suitable mechanical performance for secondary structural applications, offering a cost-effective and environmentally friendly fabrication process.
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