Sandwich Composites Manufacturing: A Review of Materials, Methods, Applications and Challenges

Abstract

Sandwich composites are a class of advanced structural materials that consist of high-strength face sheets and lightweight core layers, providing an optimal strength-to-weight ratio. These composites find wide application in the aerospace, automotive, and wind energy industries due to their superior mechanical properties, including enhanced flexural rigidity, impact resistance, and fatigue durability. This review paper provides a comprehensive examination of sandwich composite structures, encompassing their design, manufacturing processes, mechanical properties, and the latest research trends. The study methodically analyzes surface and core materials, reviews various manufacturing processes, and discusses the advantages and limitations of each method. It also addresses the aging and recycling issues of sandwich composites and proposes solutions to increase their sustainability. The research suggests that the efficiency, durability, and environmental impact of sandwich composites can be further improved through continued advances in materials science and manufacturing technology and provides guidelines for the next generation of materials for lightweight structures.