Axial compression behavior of 3D-printed biomimetic sinusoidal mesh honeycomb structures: Experimental and numerical simulation analysis

Advances in additive manufacturing have greatly expanded the design possibilities for novel biomimetic honeycomb structures. Inspired by the hierarchical architecture of spider webs and the sinusoidal micro‐geometry of the woodpecker’s beak, this study proposes a biomimetic sinusoidal mesh honeycomb (BSMH) structure, characterized by sinusoidal‐shaped cell walls coupled into a web‐like honeycomb topology. This unique configuration allows tunable mechanical and energy absorption properties. Specimens were fabricated using fused filament fabrication (FFF) and subjected to quasi‐static out‐of‐plane compression tests. Combining experiments, theoretical analysis, and finite element simulations, this study systematically investigates the axial compression behavior, collapse mechanisms and energy absorption performance of the BSMH, with a primary focus on its mechanical performance and energy absorption capacity under quasi-static loading. A parametric study examined the influence of sinusoidal amplitude ( A = 0.3–0.9 mm), wave number ( n = 1–3), and relative cell count ( q = 5, 7, 9)—on energy absorption performance. Key performance metrics-total energy absorption (EA), specific energy absorption (SEA), mean crushing force (MCF), and peak crushing force (PCF) were analyzed to identify performance trends. Results demonstrate that by adjusting these geometric parameters, the deformation modes and stress distribution can be effectively controlled, leading to significant enhancements in energy absorption efficiency. The BSMH design offers a novel approach to developing lightweight, high-performance sandwich cores, showing strong potential for practical applications—including energy-absorbing wall panels, protective liners, and lightweight yet strong components where efficient crashworthiness and a tunable load-response are essential.