Article
Licensed
Unlicensed Requires Authentication

Improvement of the mechanical properties of Kagome structures using PUR foam matrices

  • Alexandru Viorel Coşa is an Assistant Professor in the Department of Materials and Manufacturing Engineering at Politehnica University Timişoara, Romania. He is currently a PhD student in mechanical engineering and specializes in the characterization, modeling, and processing of polymer and composite materials. His research interests include additive manufacturing, mechanical testing of advanced materials, structural optimization, and the development of functional and sustainable composite systems for engineering applications.

         ,

    Sirko Geller is a research scientist and postdoc at the Institute of Lightweight Engineering and Polymer Technology, Dresden University of Technology, Germany. He completed his PhD degree at TU Dresden about the process development for manufacturing of PU-based fiber-composite structures with integrated sensor systems. His current research focuses on the development, characterization, and modeling of heavy-duty fiber-reinforced composite components based on thermosetting matrix systems. His interests further include process simulation, preforming, and the design of active composite structures for advanced lightweight applications in engineering.

         ,

    Johann Faust is a research associate and PhD student at the Institute of Lightweight Engineering and Polymer Technology, Dresden University of Technology, Germany. He holds an engineering diploma and is currently pursuing his PhD degree in the field of novel UV-curing applications for fiber-reinforced thermosets that enable immediate hardening of these composites. His other works include the development of advanced processing technologies for PU applications, process data analysis, and optimizing process-chain efficiency in thermoset manufacturing.

         , ,

    Niels Modler is Professor and Chair of Function-Integrative Lightweight Engineering at the Institute of Lightweight Engineering and Polymer Technology, Dresden University of Technology, Germany. He holds a PhD degree in Mechanical Engineering and has been involved in numerous research projects on structural health monitoring, composite materials, and sensor integration in lightweight components. His research interests include lightweight design methods, fiber-reinforced composites, material-integrated sensing and actuation, and the development of advanced structural monitoring technologies for applications in mobility, aviation, mechanical engineering, and medical devices.

         and

    Dan-Andrei Șerban is Professor and PhD Coordinator at the Department of Mechatronics, Faculty of Mechanical Engineering, Politehnica University of Timişoara, Romania. With a PhD in mechanical engineering, his research primarily focuses on metamaterial structures, thermoplastic polymers, composite materials, and polymeric foams, exploring their mechanical behavior, microstructural characterization, and numerical modeling. He investigates specific aspects such as plasticity, fracture mechanics, damage mechanics, and micromechanical behavior, with applications in lightweight engineering, automotive, and aerospace industries. His work integrates experimental studies, computational simulations, and advanced materials testing methodologies to understand structure–property relationships.

     ORCID logo EMAIL logo
Published/Copyright: January 19, 2026
Become an author with De Gruyter Brill
Submit Manuscript Author Information
Materials Testing
From the journal Materials Testing Volume 68 Issue 2

Abstract

This study investigates the opportunities of improvement of the compressive stiffness, strength, and energy absorption capabilities of metamaterial structures based on Kagome cells using rigid polyurethane (PUR) foam matrices for embedding. Three densities were considered for the Kagome structures: 142.8 kg m−3, 198.2 kg m−3, and 257.7 kg m−3, respectively (corresponding to a relative density of approximately 0.1, 0.15, and 0.2 respectively), while the density of the PUR foam was maintained constant at 90 kg m−3. The structures were incorporated in sandwich panels using thermoplastic polymer-reinforced woven glass fiber faces and were subjected to static and dynamic tests using a drop tower. Considering the weight added by the PUR matrix, the performance of the investigated structures was evaluated with respect to their density, the results showing better stiffness- and strength-to-weight ratios for the bare structures but significantly higher energy absorption capabilities for the embedded structures.

Keywords: Cellular materials; dynamic compression; energy absorption; metastructures; sandwich panels
Corresponding author: Dan-Andrei Șerban, Mechatronics, Politehnica University Timisoara, Timișoara, Romania, E-mail:

Funding source: PN-III-P2-2.1-PED-2021-1134

Award Identifier / Grant number: contract number 586PE

About the authors

Alexandru Viorel Coşa

Alexandru Viorel Coşa is an Assistant Professor in the Department of Materials and Manufacturing Engineering at Politehnica University Timişoara, Romania. He is currently a PhD student in mechanical engineering and specializes in the characterization, modeling, and processing of polymer and composite materials. His research interests include additive manufacturing, mechanical testing of advanced materials, structural optimization, and the development of functional and sustainable composite systems for engineering applications.

Sirko Geller

Sirko Geller is a research scientist and postdoc at the Institute of Lightweight Engineering and Polymer Technology, Dresden University of Technology, Germany. He completed his PhD degree at TU Dresden about the process development for manufacturing of PU-based fiber-composite structures with integrated sensor systems. His current research focuses on the development, characterization, and modeling of heavy-duty fiber-reinforced composite components based on thermosetting matrix systems. His interests further include process simulation, preforming, and the design of active composite structures for advanced lightweight applications in engineering.

Johann Faust

Johann Faust is a research associate and PhD student at the Institute of Lightweight Engineering and Polymer Technology, Dresden University of Technology, Germany. He holds an engineering diploma and is currently pursuing his PhD degree in the field of novel UV-curing applications for fiber-reinforced thermosets that enable immediate hardening of these composites. His other works include the development of advanced processing technologies for PU applications, process data analysis, and optimizing process-chain efficiency in thermoset manufacturing.

Niels Modler

Niels Modler is Professor and Chair of Function-Integrative Lightweight Engineering at the Institute of Lightweight Engineering and Polymer Technology, Dresden University of Technology, Germany. He holds a PhD degree in Mechanical Engineering and has been involved in numerous research projects on structural health monitoring, composite materials, and sensor integration in lightweight components. His research interests include lightweight design methods, fiber-reinforced composites, material-integrated sensing and actuation, and the development of advanced structural monitoring technologies for applications in mobility, aviation, mechanical engineering, and medical devices.

Dan-Andrei Șerban

Dan-Andrei Șerban is Professor and PhD Coordinator at the Department of Mechatronics, Faculty of Mechanical Engineering, Politehnica University of Timişoara, Romania. With a PhD in mechanical engineering, his research primarily focuses on metamaterial structures, thermoplastic polymers, composite materials, and polymeric foams, exploring their mechanical behavior, microstructural characterization, and numerical modeling. He investigates specific aspects such as plasticity, fracture mechanics, damage mechanics, and micromechanical behavior, with applications in lightweight engineering, automotive, and aerospace industries. His work integrates experimental studies, computational simulations, and advanced materials testing methodologies to understand structure–property relationships.

  1. Research ethics: Not applicable.

  2. Informed consent: Not applicable.

  3. Author contributions: The authors have accepted responsibility for the entire content of this manuscript and approved its submission.

  4. Use of Large Language Models, AI and Machine Learning Tools: None declared.

  5. Conflict of interest: The authors state no conflict of interest.

  6. Research funding: This work was partially funded by the Research Grant PN-III-P2-2.1-PED-2021-1134, contract number 586PED/2022.

  7. Data availability: Not applicable.

References

[1] T. Ngo, A. Kashani, G. Imbalzano, K. Nguyen, and D. Hui, “Additive manufacturing (3D printing): A review of materials, methods, applications and challenges,” Compos. B: Eng., vol. 143, pp. 172–196, 2018, https://doi.org/10.1016/j.compositesb.2018.02.012.Search in Google Scholar

[2] W. Gao et al.., “The status, challenges, and future of additive manufacturing in engineering,” Comput. Aided Des., vol. 69, pp. 65–89, 2015, https://doi.org/10.1016/j.cad.2015.04.001.Search in Google Scholar

[3] C. Bhat, C. Jiang, Y. Romario, S. Paral, and E. Toyserkani, “Critical review of metal-ceramic composites fabricated through additive manufacturing for extreme condition applications,” Mech. Adv. Mater. Struct., vol. 28, no. 10, pp. 2153–2180, 2024. https://doi.org/10.1080/15376494.2024.2376337.Search in Google Scholar

[4] T. Simsek and Z. Evis, “Additive manufacturing of overexpanded honeycomb core lattice structures and their characterization,” Mater. Test., vol. 67, no. 9, pp. 1545–1556, 2025, https://doi.org/10.1515/mt-2025-0058.Search in Google Scholar

[5] M. Kopar and A. Yildiz, “Experimental investigation of mechanical properties of PLA, ABS, and PETG 3-d printing materials using fused deposition modeling technique,” Mater. Test., vol. 65, no. 12, pp. 1795–1804, 2023, https://doi.org/10.1515/mt-2024-0100.Search in Google Scholar

[6] J. Zhu, H. Zhou, X. Wang, L. Zhou, S. Yuan, and W. Zhang, “A review of topology optimization for additive manufacturing: Status and challenges,” Chin. J. Aeronaut., vol. 34, no. 1, pp. 91–110, 2021, https://doi.org/10.1016/j.cja.2020.09.020.Search in Google Scholar

[7] Y. Saadlaoui, J. Milan, J. Rossi, and P. Chabrand, “Topology optimization and additive manufacturing: Comparison of conception methods using industrial codes,” J. Manuf. Syst., vol. 43, no. 1, pp. 178–186, 2017, https://doi.org/10.1016/j.jmsy.2017.03.006.Search in Google Scholar

[8] A. du Plessis et al.., “Beautiful and functional: A review of biomimetic design in additive,” Addit. Manuf., vol. 27, pp. 408–427, 2019, https://doi.org/10.1016/j.addma.2019.03.033.Search in Google Scholar

[9] X. Zheng et al.., “Ultralight, ultrastiff mechanical metamaterials,” Science, vol. 344, no. 6190, pp. 1373–1377, 2014, https://doi.org/10.1126/science.1252291.Search in Google Scholar PubMed

[10] X. Yu, J. Zhou, H. Liang, Z. Jiang, and L. Wu, “Mechanical metamaterials associated with stiffness, rigidity and compressibility: A brief review,” Prog. Mater. Sci., vol. 94, pp. 117–173, 2018, https://doi.org/10.1016/j.pmatsci.2017.12.003.Search in Google Scholar

[11] L. Wu et al.., “A brief review of dynamic mechanical metamaterials for mechanical energy manipulation,” Mater. Today, vol. 44, pp. 168–193, 2021, https://doi.org/10.1016/j.mattod.2020.10.006.Search in Google Scholar

[12] M. Francisco, J. Pereira, G. Oliver, L. da Silva, S. CunhaJr., and G. Gomes, “A review on the energy absorption response and structural applications of auxetic structures,” Mech. Adv. Mater. Struct., vol. 29, no. 27, pp. 5823–5842, 2021. https://doi.org/10.1080/15376494.2021.1966143.Search in Google Scholar

[13] D. Șerban, “Variation of poisson’s ratio with axial strain for three-dimensional reentrant auxetic structures,” Des. Process. Commun., vol. 2022, p. 2623601, 2022, https://doi.org/10.1155/2022/2623601.Search in Google Scholar

[14] P. Balan, J. Mertens, and M. Bahubalendruni, “Auxetic mechanical metamaterials and their futuristic developments: A state-of-art review,” Mater. Today Commun., vol. 34, p. 105285, 2023, https://doi.org/10.1016/j.mtcomm.2022.105285.Search in Google Scholar

[15] C. Inan, Z. Evis, and B. Ozturk, “Structural comparison of conventional and chiral auxetic morphed aircraft rib,” Mater. Test., vol. 66, no. 1, pp. 56–65, 2024, https://doi.org/10.1515/mt-2023-0155.Search in Google Scholar

[16] B. Gavcar, A. Shawkat Hasan, F. Atıcı, and M. Ekşi Altan, “Auxetic behavior of Ti6Al4V lattice structures manufactured by laser powder bed fusion,” Mater. Test., vol. 67, no. 7, pp. 1089–1103, 2025, https://doi.org/10.1515/mt-2025-0109.Search in Google Scholar

[17] I. Syozi, “Statistics of kagome lattice,” Prog. Theor. Phys., vol. VI, no. 3, pp. 306–308, 1951, https://doi.org/10.1143/ptp/6.3.306.Search in Google Scholar

[18] M. Scheffler and P. Colombo, Cellular Ceramics: Structure, Manufacturing, Properties and Applications, Weinheim, Wiley VCH, 2005.10.1002/3527606696Search in Google Scholar

[19] S. Song, C. Xiong, F. Tao, J. Yin, Y. Zhang, and S. Zhang, “Size effect of composite Kagome honeycomb sandwich structure reinforced with PMI foams under quasi-static bending: Experiment tests and numerical analysis,” Compos. Struct., vol. 296, no. 15, p. 115832, 2022, https://doi.org/10.1016/j.compstruct.2022.115832.Search in Google Scholar

[20] S. Song, C. Xiong, J. Zheng, J. Yin, Y. Zou, and X. Zhu, “Compression, bending, energy absorption properties, and failure modes of composite Kagome honeycomb sandwich structure reinforced by PMI foams,” Compos. Struct., vol. 277, no. 1, p. 114611, 2021, https://doi.org/10.1016/j.compstruct.2021.114611.Search in Google Scholar

[21] H. Fan, F. Meng, and W. Yang, “Sandwich panels with Kagome lattice cores reinforced by carbon fibers,” Compos. Struct., vol. 81, no. 4, pp. 533–539, 2007, https://doi.org/10.1016/j.compstruct.2006.09.011.Search in Google Scholar

[22] E. Kurt, A. Yildiz, T. İnkaya, A. R. Özcan, and İ. Gökdağ, “Lightweight design of lattice-embedded brake pedals using artificial intelligence -based optimization,” Mater. Test., vol. 68, no. 1, pp. 83–95, 2026, https://doi.org/10.1515/mt-2025-0390.Search in Google Scholar

[23] Z. Li, L. Gao, X. Zhao, M. Xie, B. Xie, and K. Li, “Compression behavior and deformation mechanism of 3D-printed Kagome lattice materials,” Mech. Adv. Mater. Struct., vol. 30, no. 21, pp. 4450–4458, 2023. https://doi.org/10.1080/15376494.2022.2097350.Search in Google Scholar

[24] I. Ullah, J. Elambasseril, M. Brandt, and S. Feih, “Performance of bio-inspired Kagome truss core structures under compression and shear loading,” Compos. Struct., vol. 118, pp. 294–302, 2014, https://doi.org/10.1016/j.compstruct.2014.07.036.Search in Google Scholar

[25] B. Lee and K. Kang, “A parametric study on compressive characteristics of Wire-woven bulk Kagome truss cores,” Compos. Struct., vol. 92, no. 2, pp. 455–453, 2010, https://doi.org/10.1016/j.compstruct.2009.08.029.Search in Google Scholar

[26] A. Nararak et al.., “Effects of Re and Co additions on lattice parameters and lattice misfit in cast Ni-based superalloys,” Mater. Test., vol. 64, no. 12, pp. 1699–0709, 2022, https://doi.org/10.1515/mt-2022-0332.Search in Google Scholar

[27] A. Coşa, R. Negru, and D. Șerban, “Development of Kagome-based functionally graded beams optimized for flexural loadings,” Eur. J. Mech. A/Solids, vol. 109, p. 105474, 2025, https://doi.org/10.1016/j.euromechsol.2024.105474.Search in Google Scholar

[28] M. Kaur and A. Srivastava, “Photopolymerization: A review,” J. Macromol. Sci., Part C, vol. 42, no. 4, pp. 481–512, 2002, https://doi.org/10.1081/MC-120015988.Search in Google Scholar

[29] L. Meza, S. Das, and J. Greer, “Strong, lightweight, and recoverable three-dimensional ceramic nanolattices,” Science, vol. 345, no. 62002, pp. 1322–1326, 2014, https://doi.org/10.1126/science.1255908.Search in Google Scholar PubMed

[30] L. Meza and J. Greer, “Mechanical characterization of hollow ceramic nanolattices,” J. Mater. Sci., vol. 49, no. 6, pp. 2496–2508, 2014, https://doi.org/10.1007/s10853-013-7945-x.Search in Google Scholar

[31] D. Șerban, R. Negru, S. Sărăndan, G. Belgiu, and L. Marşavina, “Numerical and experimental investigations on the mechanical properties of cellular structures with open Kelvin cells,” Mech. Adv. Mater. Struct., vol. 28, no. 13, pp. 1367–1376, 2021, https://doi.org/10.1080/15376494.2019.1669093.Search in Google Scholar

[32] D. Șerban, C. Marşavina, A. Coşa, G. Belgiu, and R. Negru, “A study of yielding and plasticity of rapid prototyped ABS,” Mathematics, vol. 9, no. 13, p. 1495, 2021, https://doi.org/10.3390/math9131495.Search in Google Scholar

[33] D. Șerban, A. Coşa, G. Belgiu, and R. Negru, “Failure locus of an ABS-based compound manufactured,” Polymers, vol. 14, no. 18, p. 3822, 2022. https://doi.org/10.3390/polym14183822.Search in Google Scholar PubMed PubMed Central

[34] H. Luo et al.., “Mechanical properties of foam-filled hexagonal and re-entrant honeycombs under uniaxial compression,” Compos. Struct., vol. 280, p. 114922, 2022, https://doi.org/10.1016/j.compstruct.2021.114922.Search in Google Scholar

[35] L. Gibson and M. Ashby, Cellular Solids, Structure and Properties, Cambridge, Cambridge University Press, 1997.10.1017/CBO9781139878326Search in Google Scholar

[36] E. Linul, D. Şerban, T. Voiconi, L. Marşavina, and T. Sadowski, “Energy-absorption and efficiency diagrams of rigid PUR foams,” Key Eng. Mater., vol. 601, pp. 246–249. 2014. https://doi.org/10.4028/www.scientific.net/KEM.601.246.Search in Google Scholar

[37] E. Linul, D. Șerban, L. Marşavina, and T. Sadowski, “Assessment of collapse diagrams of rigid polyurethane foams under dynamic loading conditions,” Arch. Civ. Mech. Eng., vol. 17, pp. 457–466, 2017, https://doi.org/10.1016/j.acme.2016.12.009.Search in Google Scholar

[38] L. Marşavina, D. Șerban, C. Pop, and R. Negru, “Experimental investigation of failure modes for sandwich beams,” Key Eng. Mater., vol. 754 , pp. 115–118, 2017. https://doi.org/10.4028/www.scientific.net/KEM.754.115.Search in Google Scholar

[39] E. Linul and L. Marsavina, “Assesment of sandwich beams with rigid polyurethane foam core using failure-mode maps,” Proc. Rom. Acad. – Math. Phys. Tech. Sci. Inf. Sci., vol. 16, no. 4, pp. 522–530, 2015.Search in Google Scholar

[40] Stratasys, VeroWhitePlus™ RGD835 data sheet, Rheinmünster, Germany. https://www.stratasys.com/en/materials/materials-catalog/polyjet-materials/vero/ [Accessed: Oct. 11, 2025].Search in Google Scholar

[41] Stratasys, Objet Support SUP705 Data Sheet, Rheinmünster, Germany. https://www.stratasys.com/en/materials/materials-catalog/polyjet-materials/polyjet-support-materials/sup705-705b/ [Accessed: Oct. 11, 2025].Search in Google Scholar

[42] Vosschemie, Strukturschaum H 50 AT data sheet, Uetersen, Germany, Vosschemie GmbH. https://www.vc-24.de/h50-at-strukturschaum-50-kg-m.html [Accessed: Oct. 11, 2025].Search in Google Scholar

[43] Vosschemie, Typ II B-Komponente data sheet, Uetersen, Germany, Vosschemie GmbH. https://www.vc-24.de/typ-ii-b-komponente-mdi.html [Accessed: Oct. 11, 2025].Search in Google Scholar

[44] Lanxess Performance Materials, TEPEX® dynalite 102-RG600(x)/47 data sheet, Köln, Germany, Lanxess performance materials GmbH. https://plasticsfinder.envalior.com/en/datasheet/102-RG600(x)47%25/7vVJZ [Accessed: Oct. 11, 2025].Search in Google Scholar
Published Online: 2026-01-19
Published in Print: 2026-02-24

© 2026 Walter de Gruyter GmbH, Berlin/Boston

Articles in the same Issue

  1. Frontmatter
  2. Heat treatment and corrosion resistance of 304 stainless steel metal rubber
  3. Fatigue life and damage behaviors of GFRP pipes under circumferential bend loading
  4. Topology optimization and thickness minimization of a motor plate used in tower cranes
  5. Comparison of the ballistic performance of 6063, 6061, 6082 aluminum alloy louvers under 7.62 mm bullet impact
  6. Improvement of the mechanical properties of Kagome structures using PUR foam matrices
  7. Design-dependent mechanical performance of additively manufactured hybrid hierarchical TPMS-based auxetic polymer structures
  8. Microstructure and wear resistance of in-situ synthesized TiC/TiB2 reinforced iron-based composite laser cladded coating
  9. Fabrication and analysis of 3D printed ABS-iron powder composites for radar absorption
  10. Influence of riveting speed on mechanical performance of self piercing riveted (SPR) aluminum 5182 sheets
  11. Influence of GMAW welding parameters on grain size, precipitates, and hardness in alloy 6063-T5
  12. Tribomechanical properties of direct energy deposited ceramic reinforced coatings on alloy TC4
  13. Adhesive wear performance of NiHard-4, alloyed spherical cast iron compared to high Cr cast irons and tool steels
  14. Mechanical and thermal properties of jute fiber–reinforced composites with rice husk ash filler for structural applications
  15. Analysis of an internal heat exchanger (IHX) for vehicle air conditioning systems
  16. Multi-objective optimization of process parameters in electro discharge machining of Inconel 625 superalloy with different electrode materials
  17. Optimization of 3D printing parameters for thermal conductivity of carbon fiber reinforced PLA components
  18. Effect of rainwater immersion on the wear and friction characteristics of Ni–B and Ni–B–TiO2 coatings
  19. Wear resistivity and ANFIS modeling for hybrid aluminum metal matrix composites at elevated temperatures
  20. In vitro tribological behavior of Mg2Zn1Mn/HA-Al2O3 nano-biocomposites
  21. The mine blast algorithm for the structural optimization of electrical vehicle components
  22. Influence of stitching on the interlaminar fracture toughness energy – modes I and II – of unidirectional GFRP
https://doi.org/10.1515/mt-2025-0429
Keywords for this article
Cellular materials; dynamic compression; energy absorption; metastructures; sandwich panels

Articles in the same Issue

  1. Frontmatter
  2. Heat treatment and corrosion resistance of 304 stainless steel metal rubber
  3. Fatigue life and damage behaviors of GFRP pipes under circumferential bend loading
  4. Topology optimization and thickness minimization of a motor plate used in tower cranes
  5. Comparison of the ballistic performance of 6063, 6061, 6082 aluminum alloy louvers under 7.62 mm bullet impact
  6. Improvement of the mechanical properties of Kagome structures using PUR foam matrices
  7. Design-dependent mechanical performance of additively manufactured hybrid hierarchical TPMS-based auxetic polymer structures
  8. Microstructure and wear resistance of in-situ synthesized TiC/TiB2 reinforced iron-based composite laser cladded coating
  9. Fabrication and analysis of 3D printed ABS-iron powder composites for radar absorption
  10. Influence of riveting speed on mechanical performance of self piercing riveted (SPR) aluminum 5182 sheets
  11. Influence of GMAW welding parameters on grain size, precipitates, and hardness in alloy 6063-T5
  12. Tribomechanical properties of direct energy deposited ceramic reinforced coatings on alloy TC4
  13. Adhesive wear performance of NiHard-4, alloyed spherical cast iron compared to high Cr cast irons and tool steels
  14. Mechanical and thermal properties of jute fiber–reinforced composites with rice husk ash filler for structural applications
  15. Analysis of an internal heat exchanger (IHX) for vehicle air conditioning systems
  16. Multi-objective optimization of process parameters in electro discharge machining of Inconel 625 superalloy with different electrode materials
  17. Optimization of 3D printing parameters for thermal conductivity of carbon fiber reinforced PLA components
  18. Effect of rainwater immersion on the wear and friction characteristics of Ni–B and Ni–B–TiO2 coatings
  19. Wear resistivity and ANFIS modeling for hybrid aluminum metal matrix composites at elevated temperatures
  20. In vitro tribological behavior of Mg2Zn1Mn/HA-Al2O3 nano-biocomposites
  21. The mine blast algorithm for the structural optimization of electrical vehicle components
  22. Influence of stitching on the interlaminar fracture toughness energy – modes I and II – of unidirectional GFRP
Downloaded on 11.4.2026 from https://www.degruyterbrill.com/document/doi/10.1515/mt-2025-0429/html
Scroll to top button