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Trends in Machine design Original Research

Advancements in Metal-Plastic Hybrid Structures: Experimental Analysis and Design Optimization of 3D-Printed Honeycomb Frameworks

  1. Rajkumar Panchal Department of Mechanical Engineering, Parvatibai Genba Moze College of Engineering
  2. Swapnil Mahale Department of Mechanical Engineering, Parvatibai Genba Moze College of Engineering
  3. Tejas Takalkar Department of Mechanical Engineering, Parvatibai Genba Moze College of Engineering
  4. Vishal Gaud Department of Mechanical Engineering, Parvatibai Genba Moze College of Engineering

Abstract

The exploration of metal-plastic hybrid structures has gained significant attention due to their potential for lightweight, high-strength applications across industries such as aerospace, automotive, and construction. This study investigates the experimental and design enhancements of a metal-plastic hybrid structure utilizing a honeycomb architecture produced through 3D printing. By integrating metals with plastic polymers in a honeycomb configuration, this hybrid approach aims to combine the high strength and stiffness of metals with the flexibility and lightweight nature of plastics. Various experimental tests, including compression, tensile, and impact tests, were conducted to evaluate the mechanical properties of different metal-plastic hybrid combinations and identify the optimal material blend for structural resilience and durability. The study also explores design improvements in honeycomb cell geometry and thickness, examining how these factors influence load distribution, energy absorption, and weight efficiency. Advanced simulation models were developed to predict structural behavior, validate experimental results, and guide design optimization. Findings demonstrate that specific metal-plastic hybrid compositions can achieve a 20-30% reduction in weight while maintaining comparable strength to all-metal counterparts. These insights offer valuable guidelines for designing metal-plastic hybrid structures with enhanced performance, furthering the potential for 3D-printed honeycomb frameworks in sustainable and high-performance applications

Keywords

References (11)

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