In-situ integration of inserts into integrally manufactured sandwich structures

Research output: Contribution to book/conference proceedings/anthology/reportConference contributionContributedpeer-review


The potential of sandwich structures composed of fibre composite face sheets and a cellular polymer core has been known for years. It has been shown that the efficiency of the traditional manufacturing process which consists of stacking and bonding pre-manufactured layers can be improved by utilizing an expanding matrix in a closed mould, thus creating the sandwich structure within a one-step processs. However, the problem of joining parts that are formed in the said manner by means of load application elements remained.

Therefore, a method has been developed that allows the in-situ integration of topologically optimized lightweight inserts that are tailored to the requirements of integrally manufactured composite sandwich structures. In this lecture we want to show the path of development of said inserts by means of numerical topology optimization supported by 3D-printing. Furthermore, the achieved mechanical characteristics of the resulting joint and the possibilities of integrating inserts into the manufacturing process are presented.


Original languageEnglish
Title of host publicationCellMAT 2022 - 7th International Conference on Cellular Materials
PublisherDGM - Deutsche Gesellschaft für Materialkunde e.V.
Number of pages1
ISBN (Electronic)978-3-88355-428-0
Publication statusPublished - 12 Oct 2022


Title7th International Conference on Cellular Materials
Abbreviated titleCellMAT 2022
Conference number
Duration12 - 14 October 2022
Degree of recognitionInternational event



  • Polyurethan, Lasteinleitung, Sandwich, Faserverbund