Achieving high strength and energy absorption of novel 3D printed helical layered square honeycombs

Bionics shape design of cellular structures has the potential advantage of improving their both mechanical properties and energy absorption capabilities to the conventional honeycomb structures. In this article, inspired by square porous wood and DNA double helix, we demonstrate the creation of the novel helical layered square honeycombs (HLSHs) that simultaneously exhibit high strength and excellent energy absorption capacity. In-plane compression experiments and finite element simulations revealed that helical structure can effectively strengthen every unit cell to resist local stress concentration which always leads to rapid strain localization and finally followed by catastrophic collapse. Furthermore, the stiffness, strength and energy absorption capability can be continuously improved by increasing the number of helical layers. More specifically, the HLSH-4L (4 layers) exhibits higher collapse stress (∼176 %) and specific absorption energy (∼502 %) compared with that of regular square honeycomb (RESH). The investigation of deformation and failure behavior show that the helical structure can supply high cell-buckling resistance and facilitate the “X” shape deformation band. Besides, the helical structure also caused the transition of failure mechanisms from printing fibers tearing in RESH to layer cracking in HLSHs. This study can present insight into the design of lighter and stronger honeycomb.