To achieve the integrity of the honeycomb structure without interlocking or bonding, a 3D braided honeycomb structure was designed and developed using natural fiber (jute) reinforced epoxy resin. To optimize the in-plane compressive performance of 3D braided composite honeycombs, the effects of resin, unit cell opening angle, and joint wall length on the in-plane compressive strength, deformability, stiffness and energy absorption were investigated. Furthermore, a theoretical model was established between braiding parameters, geometric parameters of honeycomb cell structure, and in-plane compressive modulus. It is found that if 3D braided composite honeycombs are designed for high load-bearing capacity, it is necessary to reduce the resin strain to failure, increase free wall columns, align the angle between the free wall with the main loading direction, or load along the braiding direction. If the design objective is to maximize the energy absorption, the number of cell rows must be maximized. This study establishes the relationship between braiding parameters, honeycomb geometric parameters, and the in-plane compression performance of the 3D braided composite honeycomb, providing a reference for its structural design and performance optimization.@en

This paper presents the design and development of three-dimensional braided honeycomb structures. The basic principles and braiding process are described. The relationship between braiding parameters and honeycomb geometric parameters is established and several three-dimensional (3D) braided honeycomb fabrics are introduced. Based on the principle of the 3D braiding ‘four-step’ method, the interlaced state of yarns can be changed by controlling the movement of yarn carriers, so the separation and combination of the braid can be controlled, then 3D braided honeycomb fabric can be formed. As the number of braiding cycles of wall length increases, the relative density will gradually decrease, but the number of braiding cycles of free wall length has a greater effect on the relative density. When the number of columns of yarns participating in wall thickness increases, the relative density will gradually increase. The relative density also showed a positive correlation with the braiding angle. With the increase of the opening angle, the relative density gradually decreases, although there is a minimum point after which a little increase is observed. This paper provides significant guidance for designing various 3D braided honeycomb structures and evaluating their relative density, and can be a reference for the design and development of new honeycombs structures.

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