Applied Composite Materials

https://doi.org/10.1007/s10443-020-09837-z

Fabrication and Characterization of Hemp Fibre Based 3D

Printed Honeycomb Sandwich Structure by FDM Process

Sheedev Antony1   · Abel Cherouat1 · Guillaume Montay2

Received: 27 July 2020 / Accepted: 19 October 2020

© Springer Nature B.V. 2020

Abstract
Natural fibre composites have been trending in the industries recently due to their better
recyclability, renewability, biodegradability. Fused Deposition Modelling (FDM) is one of
the widely used additive manufacturing process for the fabrication of simple and complex
structures. In this study, hemp/PLA 3D printed honeycomb sandwich structures were fab-
ricated by FDM process and mechanical behaviour was characterized. Initially, the ten-
sile behaviour of hemp fibre/PLA filaments and the 3D printed composite specimens with
an infill angle of 0°/90°, -45°/ + 45° were investigated. Honeycomb cores were fabricated
and their mechanical behaviour in flatwise, edgewise directions were analysed. Later, hon-
eycomb sandwich structures were fabricated using core and skin parts. Compression and
4-Point bending tests were performed to characterize the mechanical behaviour. Analyti-
cal analysis was also performed to predict the mechanical properties of the honeycomb
sandwich structure knowing the properties of the cell wall material. Some small-scaled
automotive and aerospace prototypes were fabricated to assure the application of this
methodology.

Keywords  Natural fibre composites · Hemp fibre · 3D printing · FDM process ·

Honeycomb sandwich structure

1 Introduction

Natural fibre thermoplastic composites are being used in different industries recently due
to their low price, low density, low energy consumption, renewability, recyclability, bio-
degradability, less health risk while tooling, light weight, etc.[1]. Additive manufactur-
ing (AM) is “a process of joining materials to make objects from 3D model data, usually
layer upon layer, as opposed to subtractive manufacturing methodologies” [2]. AM reduces
the production cost, wastage of material, design-manufacturing cycle, etc.[3]. Fused Dep-
osition Modelling (FDM) material extrusion process is one of the widely used additive

* Sheedev Antony
sheedev.antony@utt.fr
1
University of Technology of Troyes, GAMMA3‑INRIA 12 rue Marie‑Curie, BP 2060,
10010 Troyes, France
2
University of Technology of Troyes, LASMIS 12 rue Marie‑Curie, BP 2060, 10010 Troyes, France

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 Applied Composite Materials

manufacturing process where filaments will be heated and extruded through nozzle tip
that will be deposited on the platform layer by layer to manufacture the parts [4, 5]. FDM
allows manufacturing of complex-shaped parts for different applications in automotive,
aerospace, construction, etc.[6–8].
In the literature, there are only few studies on fibre reinforced thermoplastic compos-
ites using FDM process. Shofner et al. [9] introduced nano-fibre reinforced ABS compos-
ites by FDM method. Feedstock filaments with single-walled carbon nanotube and ABS
were studied. It was observed that addition of 10 wt% of carbon nanotubes provides 40%
and 60% improvement in the tensile strength and tensile modulus. Zhong et al. [10] stud-
ied the processability of glass fibre reinforced ABS composite with different glass fibre. It
was found that tensile strength and surface rigidity improved significantly. Gray et al. [11]
introduced thermotropic liquid crystalline polymer fibre reinforced polypropylene compos-
ites filament for FDM. Better tensile strength and good functionality were analysed and it
was observed that tensile properties of the monofilaments were dependent on the diameter,
L/D ratio and apparent shear rate due to fibril alignment. Recently, the natural fibre based
3D printing got the attention of the researchers. Matsuzaki et  al. [12] proposed printing
of jute yarn/PLA based using simultaneous impregnation process and mechanical proper-
ties were investigated. It was noted that the specimens provides a longitudinal stiffness of
5.11 ± 0.41 GPa, strength of 57.1 ± 5.3 MPa and strain at failure of 1.81 ± 0.44%. Similarly,
continuous flax fibre/PLA based composites were manufactured by fused filament fabrica-
tion process by Duigou et  al. The tested specimen shows better longitudinal mechanical
properties compared to other 3D printed biocomposites [13]. Depuydt et al. [14] prepared
new type of fibre reinforced filament materials for Fused Deposition Modelling applica-
tions with bamboo and flax fibres/PLA. Most of these studies didnot explore the applica-
tion of the 3D printed composites well.
Honeycomb sandwich structures are manufactured by attaching two thin skins on top,
bottom of low-density sandwich core. Compression and flexural behaviour of the honey-
comb structure is important. The mechanical behaviour is highly depending on the core
material, skin material, thickness of the core, skin materials, etc. Recently, natural fibre
composites are utilized to fabricate honeycomb cores for sandwich panels, which will pro-
vide different advantages to the structures like vibration control, better energy absorption
properties, good impact behaviour, etc. Several researchers were focused on the manufac-
turing and characterization of natural fibre based composites. In previous studies, Antony
et al. [15] fabricated hemp fibre woven fabrics/polypropylene based honeycomb sandwich
structure by thermal-compression process and investigated the compression and flexural
behaviour. It was observed that this honeycomb sandwich structure has good potential to
be utilized in many aircraft or automotive parts. Zuhri et  al. [16] investigated the com-
pression at quasi-static rates of strain of square and triangular honeycomb core made of
commingled flax fibre reinforced polypropylene and polylactide made by simple slotting
technique. The compression strength and specific energy absorption characteristics of the
structures were obtained and it was observed that square honeycomb cores are greater
than triangular honeycomb cores. Similarly, honeycomb core made of jute fibre vinyl ester
matrix was manufactured and the mechanical properties were studied by Stocchi et al. [17].
High compression properties were observed and it was concluded that it has potential to be
the alternative to standard cores. Petrone et al. [18] manufactured flax fibre / polyethylene
honeycomb sandwich structure, acoustic properties were investigated and better damping
values were obtained without increasing the weight. Vitale et al. [19] studied the mechani-
cal properties and failure modes of jute reinforced polyester sandwich structure manufac-
tured by vacuum assisted resin transfer moulding (VARTM) under three-point bending

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Applied Composite Materials

test. The obtained results were compared with analytical results and good agreements were
found. Roslan et al. [20] studied the compression, flexural behaviour of square and trian-
gular bamboo-epoxy sandwich structure composite. It was observed that triangular hon-
eycomb provide more energy absorption compared to square honeycomb structure and it
was concluded that smaller cell size provides better energy absorption properties. Du et al.
[21] investigated the creep behaviour of cotton linter /epoxy based honeycomb sandwich
structure in ambient and relative humidity condition. It was observed that higher relative
humidity creates significant creep strain acceleration.
All this study demonstrates the possibilities of natural fibre composites in the fabrica-
tion of honeycomb sandwich structures. As mentioned above, 3D printing technique pro-
vide many advantages in the manufacturing of components. The integration of natural fibre
composites and 3D printing by FDM method can contribute lot advantages in the produc-
tion of structures in different industries especially in automotive and aerospace industries.
The aim of this study is to fabricate 3D printed honeycomb sandwich structure by
FDM process and characterize their mechanical properties. Initially, the tensile behaviour
of hemp fibre/PLA based filament will be studied. Hemp/PLA 3D printed composite ten-
sile specimens will be fabricated with an infill angle of 0°/90°, -45°/ + 45° and the tensile
behaviour will be investigated. Honeycomb sandwich core will also be fabricated and the
mechanical behaviour will be analysed. Later, honeycomb sandwich cores with two skins
will be fabricated for compression and flexural tests. Analytical analysis will be also per-
formed to predict the mechanical properties of the honeycomb sandwich structure knowing
the properties of the cell wall material. Small-scaled 3D printed automotive and aerospace
prototypes will also be manufactured to demonstrate the feasibility of this methodology.

2 Materials and Methods

In this section, the materials, fabrication of 3D printed specimens and cores, mechanical
test to characterize the behaviour of filaments, 3D printed specimen, 3D printed cores,
sandwich honeycomb structures will be detailed.

2.1 Hemp/PLA Filament

Hemp/PLA filaments with 20–25% of hemp with a diameter of 1.75  mm were provided
by hemprinted [22]. Tensile tests were performed with a crosshead speed of V = 1  mm/
min with a static load using INSTRON 4484 machine at ambient temperature. Paper frame
technique (Fig. 1) were used to fix the filaments to the tensile machine jaws [23]. Five fila-
ment specimens with a gauge length of 30 mm were tested and force versus displacement
curves were obtained.

2.2 Hemp/PLA 3D Printed Specimen

3D printing process consist of different steps in building a solid part from digital files
starting from CAD file, STL file, slicing, printing and final part (Fig. 2). Hemp/PLA ten-
sile dogbone specimens according to ASTM D638-10 standard [24] for tensile test were
modelled in CATIA and CAD files were created. The CAD files were converted to STL
files and the part is sliced using the slicing software Slic3r slicer. The slicing of the layers
and the path of the tool were designed. Repetier host v1.0.6 software were used to control

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 Applied Composite Materials

Fig. 1  Tensile test setup for hemp

/ PLA filament

Fig. 2  Different Stages in 3D Printing Process

the 3D printer and the parts were printed (Fig.  3). The specimens were created with an
infill angle of 0°/90°and -45°/ + 45° (Fig. 4). The 3D printer was set in a room with con-
stant room temperature and different trial & error printing experiments were conducted to
identify the appropriate printing parameters. The printing parameters were set as: extruder
temperature = 180 °C, bed temperature = 55 °C, printing speed = 20 mm/s, minimum noz-
zle diameter = 0.6  mm, infill density = 100%, layer thickness = 0.2  mm, extrusion multi-
plier = 100%, shell thickness = 0.8 mm, top/bottom thickness = 0.8 mm. (Table 1).
Uniaxial tensile were performed at ambient temperature with a crosshead speed of
5 mm/min using INSTRON 4411 machine with a static load. Five specimens were tested
and force versus displacement curve for each tests were obtained. Specimens were having a
cross-section of 60.8 mm (19 mm × 3.2 mm) and gauge length of 50 mm.

2.3 Hemp Fibre 3D Printed Honeycomb Core

Honeycomb core part was designed in CATIA© with desired dimensions (Table  2)
and skin part were 3D printed (Fig.  5). Compression tests according to ASTM C365

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Applied Composite Materials

Fig. 3  Home-made 3D printing machine and setup

/ C365M – 16 standard for flatwise and ASTM C364 / C364M – 16 standard for edge-
wise were performed to investigate the mechanical behaviour of the core part (Fig. 6).
Force versus displacement curve were obtained for both tests. The flatwise and edge-
wise core have a cross-sectional area of 247.50mm2 and ­150mm2 respectively.

2.4 Hemp Fibre 3D Printed Honeycomb Sandwich Structure

Honeycomb core with dimension of 25 mm x 25 mm for compression tests and 150 mm
x 25 mm for 4-point bending tests were fabricated. The core skins with desired dimen-
sions were also fabricated. The skins parts were attached to the top and bottom of
the core parts with adhesives. The compression test and flexural test (4-point bending)
were performed according to ASTM C365/C365M standard and ASTM D790 stand-
ard respectively using INSTRON 4411 machine with a static load, cross-head speed
of 5  mm/min at ambient temperature (Fig.  7). The compression test specimens were
placed between the jaws of the mechanical test machine and compression forces were
applied. Similarly, the flexural test specimens were placed on top of two cylindrical
shaped indenters with a support span of 100  mm and two cylindrical shaped indent-
ers on top of the specimen with a load span of 50  mm. Flexural force was applied
from the top. Force versus displacement curve for compression and 4-point bending
test were obtained. Images were also captured during the mechanical using high-speed
for observing the response at different time interval.

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Fig. 4  3D printed hemp/PLA tensile specimens: (a) 0°/90° and (b) -45°/ + 45°

Table 1  3D printing parameters. Parameters Values

Extruder temperature 180 °C

Bed temperature 55 °C
Printing speed 20 mm/s
Minimum nozzle diameter 0.6 mm
Infill density 100%
Layer thickness 0.2 mm
Extrusion multiplier 100%
Shell thickness 0.8 mm
Top/bottom thickness 0.8 mm

Table 2  Geometrical parameters Cell size (D) 6 mm

of 3D printed honeycomb core
and skin
Cell thickness (t) 2 mm
Core width (b) 25 mm
Core thickness (H) 25 mm
Skin thickness (h) 1.25 mm
Cell length (m, n) 3.46 mm

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Applied Composite Materials

Fig. 5  3D printed honeycomb

core part: (a) CAD part and (b)
Real part

Fig. 6  Compression test of 3D
printed honeycomb core: (a)
Flatwise and (b) Edgewise

Fig. 7  (a) Compression and (b) flexural tests of 3D printing honeycomb sandwich structures

3 Results and Discussions

In this section, the results obtained from the mechanical test of filament, 3D printed
composite specimen, 3D printed honeycomb sandwich structure will be discussed.

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Fig. 8  Stress versus strain curve

of hemp/PLA filament

Table 3  Mechanical properties of Tensile modulus Tensile strength

hemp/PLA filaments (MPa) (MPa)

1534.45 ± 23 28 ± 3.6

3.1 Hemp/PLA Filament

Stress versus strain curves for hemp/PLA filament were plotted (Fig. 8) and the mechanical
properties were calculated (Table 3). It is noted that the stress versus strain curve shows
initially the linear elastic deformation and the elastic modulus is estimated from the initial
slope of the curve in the range of 0.1–0.5% strain. As the test progress, the curve shows
non-linear behaviour due to transfer from elastic to plastic behaviour. Later, the curve fol-
lows the plastic behaviour until it reaches maximum strength and fails. The micro cracks
formed during the elongation of the filaments was the main cause of the failure. As men-
tioned before, the filaments exhibit elastic behaviour in the beginning up to 18-20  MPa
and as the test progress, the filament shows viscoelastic behaviour. It breaks between
25-30 MPa and provides tensile modulus between 1500 to 1575 MPa. It must be noted that
the purpose of this study is to reduce the plastic content without comprising the mechani-
cal behaviour and reduce the cost of the final part. The PLA used to fabricate the filaments
have a Young’s modulus of around 2000  MPa (75%) and the hemp fibre powder have a
Young’s modulus of around 700 MPa (25%). According to the mixture rules, this compo-
nents can provide 1675 MPa which is approximately achieved.

3.2 Hemp/PLA 3D Printed Specimen

Stress versus strain curves for 3D printed specimens were plotted and similar behaviour
as the filaments was observed (Fig. 9). Initially, the elastic behaviour was exhibited by
the specimens and as test progress, it is transited to plastic response. It was noted that

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Fig. 9  Tensile stress versus

tensile strain curve of hemp/PLA
3D printed specimens

by 0°/90° and -45°/ + 45° specimens shows differences in the behaviour as expected.

The printing orientation is obviously a key factor of the mechanical properties of 3D
printed specimens. As the layers are oriented in the direction of loading, 0°/90° ori-
entation printed specimens have better ability to share the load between the layers. In
the case of -45°/ + 45° orientation printing specimens have restriction on carrying and
transferring the load. Moreover, the chances of delamination of layers are high in this
case. Cantrell et  al. [25] performed a detailed study of the printing orientation on the
mechanical properties and it was observed that 0°/90° provides better tensile properties.
Initial elastic behaviour was shown up to 8-10 MPa and later, viscoelastic behaviour was
exhibited up to 12–17.5 MPa and it fails. Similar behaviour was shown by the specimen
prepared by 0°/90° and -45°/ + 45° but 0°/90° provides slightly better properties com-
paratively. 0°/90° provides a tensile modulus between 900-950 MPa whereas -45°/ + 45°
provides 775-825 MPa (Table 4). The composites have an approximated volume density
of 4.75 × 10–4 g/cm3. It is also observed that the 3D printed specimen has less mechani-
cal properties compared to the raw material filament. One of the drawbacks of FDM
process is the filaments are molten at high temperature and as a consequence the poly-
mer will be degraded. Moreover, the natural fibre composites have the limitation of tem-
perature, which is a significant disadvantage that can reduce the mechanical properties
after exposed to high temperature. Several studies have been performed by researchers
to improve the mechanical properties of polymers [26] and natural fibres [27] which
will be exposed to high temperature during FDM.

Table 4  Mechanical properties of Specimen Tensile modulus Tensile strength

hemp/PLA 3D printed specimens (MPa) (MPa)

0°/90° 922.45 ± 16 15.74 ± 3.2

-45°/ + 45° 797.90 ± 12 14.88 ± 2.5

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Fig. 10  Stress versus strain curve of hemp/PLA 3D printed honeycomb core: (a) Flatwise, (b) Edgewise

Table 5  Mechanical properties of Specimen Compressive modulus Compressive strength

hemp/PLA 3D printed core (MPa) (MPa)

Flatwise 854.21 ± 32.5 47.44 ± 6.2

Edgewise 628.08 ± 28.3 15.46 ± 3.15

3.3 Hemp/PLA 3D Printed Honeycomb Core

Compressive stress versus strain curve for edgewise and flatwise core were plotted
(Fig.  10). The core provides a compressive strength between 40-55  MPa and between
12-20 MPa for flatwise and edgewise respectively. The compressive modulus was about
825-900  MPa for flatwise and 600-660  MPa for edgewise (Table  5). The flatwise test
result shows linear elastic behaviour and it is noticed that the 3D printed core provided
very good compressive strength. The presence of the layers restricts the collapse of the
core and provided good compressive properties. In contrary, the hemp/PP core made by
compression moulding process have very less compressive properties comparatively. In
the case of 3D printed core, each layer involves in providing strength to the cell wall
structure. As the test progress, it start showing plastic non-linear behaviour which result
in the cell wall buckling and folding of the walls. Later, cell walls start collapsing and
start contacting each other which cause a small densification behaviour in the end. Simi-
larly, the edgewise shows linear elastic behaviour in the starting. Due to the thin cell
wall until the maximum load and the hexagonal structure, the wall collapse very ear-
lier compared to the flatwise core. Compressive strength of different honeycomb cores
from the literature was compared (Table  6). It is noticed that the hemp polypropylene
core made by thermal compression moulding and jute/vinyl ester resin injection mould-
ing process provided a compressive strength around 7  MPa and 15  MPa respectively.
Similarly, aluminium plascore, stainless steel plascore, euro composite, Hexcel HRH 10
Nomex provided only 9.37 MPa, 2.4 MPa, 1.4 MPa, 0.9 MPa respectively. It was found
that 3D printed hemp/PLA core provides high compression strength comparatively.

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Table 6  Comparison of geometry and compressive strength of honeycomb cores

Core Cell Cell Core Compressive Reference
size thickness height strength
d (mm) t (mm) H (mm) σc (MPa)

Hemp/PLA 3D printed honeycomb 6 2 25 47.44 Experiment

Hemp/PP honeycomb 6 2 25 6.51 [15]
Jute/VE 6 1.43 10 14.99 [17]
honeycomb
Aluminium 6.4 0.1 15.8 9.37 [17]
plascore
Stainless steel plascore 9.5 - 12.7 2.41 [17]
Euro 6.4 - 12.7 1.4 [17]
composite
Hexcel HRH 10 Nomex 4.7 0.15 19 0.9 [17]

3.4 Hemp/PLA 3D Printed Honeycomb Sandwich Structure

Stress versus strain curves of 3D printed honeycomb sandwich structure for compres-
sion and flexural test are plotted (Fig. 11). In compression test, initially load increases
linearly and the cell wall starts buckling. The cell walls began to fold and the core start
deforming plastically. Later, cell wall contact each other as the test progress and the
load start increasing slowly as the consequence of densification. In flexural test, the load
start linearly and as the test progress, there is interaction between the skin and core that
create slight perturbation in the linear part of the curve. Due to the high rigidity of the
core, the honeycomb core breaks catastrophically as it reaches the maximum stress. The
images captured at different time intervals during the tests were presented in Fig. 12. In
compression test, at displacement u = 5 mm, the beginning of buckling can be observed
and at u = 10  mm, all the cell walls buckle. At u = 16  mm, the cell walls contact and
densification can be clearly observed. In flexural test, at u = 1.5 mm, the core start bend-
ing slightly and at u = 3 mm, the skin starts to detach from the core. As the test progress,
skin removes from the core completely and finally the structure fails completely. It can

Fig. 11  Force versus displacement curve of hemp/PLA 3D printed honeycomb sandwich structure: (a)
Compression test, (b) Flexural test

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Fig. 12  Images captured during different time interval during the experiments: (a) Compression test, (b)
Flexural test

be concluded that the structure provides very good compression property but bad flex-
ural property.
Several failure mechanisms in 3D printed honeycomb sandwich structure were found
during the mechanical test (Fig. 13). Skin failure was the initial failure in the mechani-
cal test. The load was acting on the skin and as the maximum load limit reaches, the
skin start cracking. As the core is rigid comparatively, the core start breaking at low

Fig. 13  Failure mechanism in hemp / PLA 3D printed honeycomb sandwich structure: (a) Skin failure, (b)
Core failure, (c) Core/skin interface failure, (d) Buckling

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displacement. After the force reach to a point where the interface between core and skin
start damaging.

4 Analytical Estimation of Parameters and Mechanical Properties

of Honeycomb Sandwich Structure

The area of hexagonal honeycomb structure can be calculated by considering a unit

structure U (Fig.  14) [28]. The number of unit structures NU in a honeycomb with
(2a + 1) x (2a + 1) cells i.e. for example a = 1, then 3 × 3 is calculated as:

NU = 8a2 + 14a + 6 (1)

And the nominal stress 𝜎 can be estimated by:

F
𝜎=
NU ∗ AU (2)

where F is the out of plane force and AU is the surface area of unit.
The relative density of honeycomb hexagonal structures can be calculated by [29]:
[ ]
𝜌U t m+n
= (3)
𝜌M n (m + n ∗ sin 𝜃) cos 𝜃

where 𝜌U is the density of the unit, 𝜌M is the density of the material, t is the thickness
of the cell wall, 𝜃 is the angle of the cell, m and n are the length of the cell (Fig. 14).
Relative density of a perfect hexagonal honeycomb is 𝜌U = √ with m = n and 𝜃=30°.
𝜌 8 t
M 3 3n
It can be observed that the relative density is directly proportional to the thickness of
the cell wall. As the wall thickness increases, the force required to bend and collapse the
cell wall which provide high modulus [29][29][29]. The geometry of cell and the calcu-
lated relative density is presented in Table 7.
The in-plane Young’s moduli E1 , E2 and the out of plane Young’s modulus E3 of per-
fect hexagonal honeycomb (m = n and 𝜃=30°) can be calculated by [31]:

Fig. 14  Unit cells and unit

structure

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Table 7  Geometry of cells and m n t 𝜃 𝜌U

the calculated relative density for (mm) (mm) (mm) (°)
𝜌M
hemp/PLA honeycomb structure
3.46 3.46 2 30 0.89

� �
� �3
t 4
E1 = Ew (4)
n
√
3

� �
� �3
t 4
E2 = Ew (5)
n
√
3

� �
t 2
� �
E3 = Ew (6)
n
√
3

where Ew is the cell wall Young’s modulus (922.45 MPa) that is obtained from tensile test.
The equations above show the high anisotropic behaviour of the structure.
Similarly, the in plane shear modulus G12 and the out of plane shear moduli G13 and G23 of
perfect hexagonal honeycomb (m = n and 𝜃=30°) can be calculated by [33]:
� �
� �3
t 1
G12 = Ew (7)
n
√
3

� �
t 1
� �
G13 = Gw (8)
n
√
3

� �
t 1
� �
G23 = Gw (9)
n
√
3

with Gw is the shear modulus of cell wall (797.90 MPa) that is obtained by simple in plane
shear test.
Poisson’s ratios of hexagonal honeycomb structure can be estimated as 𝜗23 = 1 ,
𝜗13 = 𝜗23 = 0 , 𝜗31 = 𝜗23 = 𝜗w where 𝜗w is the Poisson’s ratio of cell wall (0.32).
The properties were estimated and presented in the Table 8.
The mechanical properties of hexagonal honeycomb is highly depend on the geometry
especially on the cell angle ( 𝜃 ) and ratio of the cell wall length (m/n). The general equations

Table 8  Estimated properties of E1 E2 E3 G12 G13 G23 𝜗12   𝜗13   𝜗23  

hemp/PLA honeycomb structure (MPa) (MPa) (MPa) (MPa) (MPa) (MPa)

411.16 411.16 615.68 102.79 268.15 268.15 1 0 0

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Fig. 15  Predicted curve of 𝐄1
versus Cell wall angle 𝜃

Fig. 16  Predicted curve of 𝐄2
versus Cell wall angle 𝜃

for E1 , E2 , E3 is presented below [31]. The effect of the parameters such as 𝜃 , m/n ratio on E1 ,
E2 , E3 is estimated and plotted below (Fig. 15, 16, 17)
( )
( )3
t cos𝜃
E1 = Ew m (10)
n
n
sin2 𝜃 + sin3 𝜃

( )3 sin𝜃 + m
( )
t n
E2 = Ew (11)
n cos3 𝜃

( 1m )
t
( )
2 n
+1
E3 = Ew m (12)
n cos𝜃 + sin𝜃 cos𝜃
n

From the above curves, it can be assured that the cell wall angle and ratio between the
lengths of cell wall have great influence in the mechanical properties of the honeycomb

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Fig. 17  Predicted curve of 𝐄3
versus Cell wall angle 𝜃

sandwich structure. Similarly, all other mechanical properties can be predicted by knowing the
material properties of the honeycomb structure wall.
Considering the elastic buckling (eb), the plateau stress is zero in 𝜎1 direction as the
inclined wall bend and lead to densification. For regular hexagonal honeycomb, the elastic
bucking can be calculated as:
( ) 3 ( ) 3
𝜎2eb = Ew 0.22 t
n
and 𝜎3eb = Ew 5.2 t
n
(10).
respectively in 𝜎2 and 𝜎3 directions. It is noticed that 𝜎3eb is 20 larger than 𝜎2eb [29].
Similarly, the plastic collapse (pc) of regular hexagonal honeycomb can also be calculate
as:
( )2 ( )5
𝜎1  = 𝜎2  = 𝜎y 23 and 𝜎3  = 5.6 𝜎y (11).
pc pc t pc t 3

n n
with 𝜎y as the yield stress (11.5 MPa).
The crushing strength (cs) of regular hexagonal honeycomb can be estimated as [29]:
( )2 ( )5
𝜎1cs = 𝜎2cs = 49 𝜎fw nt and 𝜎3cs = 6.6 𝜎y nt
3

with 𝜎fw as cell wall fracture (15.74 MPa).

The elastic buckling, plastic collapse and crushing strength of hemp / PLA honeycomb
structure were estimated using the above equations and presented in Table 9.
The elastic buckling stress is observed as 926.25  MPa in the vertical direction and
39.19 MPa in the longitudinal direction. The plastic collapse is about 25.76 MPa and crushing
strength is about 41.55 MPa in the vertical direction. The analytic analysis has been able to
provide sufficient details about different properties of the honeycomb core structure just know-
ing the basic properties. This analysis can assist in designing a better honeycomb structure by
predicting the mechanical properties prior to manufacture them.

Table 9  Estimated elastic buckling, plastic collapse and crushing strength of hemp / PLA honeycomb struc-
ture
pc pc pc
𝜎1eb 𝜎2eb 𝜎3eb 𝜎1 𝜎2 𝜎3 𝜎1cs 𝜎2cs 𝜎3cs
(MPa) (MPa) (MPa) (MPa) (MPa) (MPa) (MPa) (MPa) (MPa)

0 39.19 926.25 2.56 2.56 25.76 2.34 2.34 41.55

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Applied Composite Materials

5 Demonstration of Hemp / PLA 3D Printed Parts

Composite materials are widely used in automotive industries due to several reasons. They
can reduce the weight of the vehicles, which will improve the performance and the fuel
efficiency. It can protect the vehicles from corrosion and provide better energy absorption
properties. Moreover, composite materials provide flexibility of design and allow the man-
ufactures to fabricated complicated parts effortlessly. Natural fibre composites are cheap
compared to many conventional materials and 3D printed parts can reduce the wastage
of materials. One of the car part which damage regularly and expensive to replace is fog
light cover on the car front bumper. The addition of natural fibre composite honeycomb
design not only provide the good look to the car but also it gives better impact strength and
contribute in the weight reduction. Similarly, UAV utilizations are widely expanding in dif-
ferent fields such as agriculture, science, commercial, etc. As the demand of high number
of requirements of UAVs increases, the price is starting to increase. The design of UAVs
are crucial to reduce the weight of the structure and due to this, composite materials are
extensively used in manufacturing of UAV frames. The 3D printed natural fibre composite
design can be adapted in the frame design, which will reduce the weight, reduce the price,
improve the design, etc. Small-scaled prototype of car fog light cover and UAV frame that
is designed and manufactured by 3D printing using hemp/PLA is presented in Fig. 18.

6 Conclusion

In this study, the fabrication and characterization of 3D printed hemp composite honey-
comb structure were executed. Initially, the tensile properties of hemp/PLA filaments were
studied by paper frame technique. It was observed that the filament have a tensile modulus
about 1530 MPa and a tensile strength around 28 MPa. Specimens were printed in 0°/90°
and -45°/ + 45° infill angle and tensile were studied. It was noticed that 3D printed hemp/
PLA specimens can provide a tensile modulus of 750-950 MPa and a tensile strength of
14.5-16  MPa. Honeycomb cores were designed, 3D printed and compressive properties
were studied. The cores have a compressive modulus about 850 MPa and a compressing
strength of 47 MPa in flatwise direction, whereas the cores have a compressive modulus

Fig. 18  Demonstration of CAD and 3D printed car fog light cover and UAV frame small-scaled prototypes

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 Applied Composite Materials

about 625 MPa and a compressing strength of 15 MPa in edgewise direction. Honeycomb

sandwich cores were fabricated for compression, flexural tests and skins were attached
with adhesives. Experimental were performed to study the compressive and flexural behav-
iour of the structures. It was observed that the compression test response consist of three
stages: elastic, buckling and densification, whereas the 4 point bending response consist of
elastic and failure stages. Analytical analysis was also performed to predict the mechanical
properties of the honeycomb sandwich structure knowing the properties of the cell wall
material. This analysis provided sufficient mechanical properties of the honeycomb struc-
ture which can assist in designing a better final part.Some small-scaled prototypes of auto-
motive and aerospace parts were fabricated and demonstrate to confirm the application of
this methodology. It can be concluded that this methodology have lot of potential in the
industries especially in manufacturing and designing of prototypes.

Acknowledgements  The authors would like to acknowledge the valuable financial support of University
of Technology of Troyes and Grand Est Region France—European Regional Development Fund (FEDER)
during this research.

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