Leveraging Variable Density Honeycomb Structures for Innovative Design in Mission-Critical Embedded Devices

The imperative for lightweighting technologies, paramount in mission-critical cyber-physical systems (CPSs) including aerospace, automotive and allied sectors, hinges upon optimizing energy efficiency and curbing product weight. Honeycomb structures, celebrated for their exceptional strength-to-weight ratio, have indisputably guided the pursuit of lightweight design. This paper expounds upon the versatility of honeycomb structures by scrutinizing their in-plane mechanical attributes. Leveraging finite element simulations and polynomial fitting, we enhance the prevailing equivalent elastic modulus model for uniform honeycomb structures, expanding its domain to encompass a broader spectrum of relative density values. Deliberations ensue concerning the model’s constraints and its inapplicability to nonuniform honeycomb structures. The investigation introduces nodes as pivotal influencers in the mechanical comportment of nonuniform honeycomb structures, delineating the nexus between the equivalent elastic modulus and node dimensions through a fusion of finite element simulations and mechanical experimentation. Furthermore, this research delves into the tenets and constructs of density-based variable density methodologies within the ambit of topology optimization, with an overarching goal of maximizing stiffness. We furnish a holistic design protocol for optimizing honeycomb structures, underscored by a pragmatic instantiation of the density-based variable density approach. Scrutinizing the geometric interplay between honeycomb structures and design spaces, we posit an innovative paradigm employing concentric circles to approximate cellular envelopes, streamlining numerical cartography and the conversion of optimization outputs into variable density honeycomb configurations. Evaluation of the in-plane mechanical attributes of variable density honeycomb structures reveals that TPU material augments the resilience of both uniform and variable density honeycomb structures, whereas topology optimization amplifies specific stiffness and resilience modulus in variable density honeycomb structures relative to their uniform counterparts. This study sheds light on the complexities of honeycomb structures, providing valuable insights for their optimization in lightweight applications.