Impact response of a low-cost randomly oriented fiber foam core sandwich panel

Three-dimensional fiber-reinforced foam cores may have improved mechanical properties under specific strain rates and fiber volumes. But its performance as a core in a composite sandwich structure has not been fully investigated. This study explored different manufacturing techniques for the three-dimensional fiber-reinforced foam core using existing literature as a guideline to provide a proof of concept for a low-cost and easily repeatable method comprised of readily available materials. The mechanical properties of the fiber-reinforced foam were determined using a three-point bend test and compared to unreinforced polyurethane foam. The foam was then used in a sandwich panel and subjected to dynamic loading by means of a gas gun (10³ s⁻¹). High-strain impact tests validated previously published studies by showing, qualitatively and quantitatively, an 18–20% reduction in the maximum force experienced by the fiber-reinforced core and its ability to dissipate the impact force in the foam core sandwich panel. The results show potential for this cost-effective manufacturing method to produce an improved composite foam core sandwich panel for applications where high-velocity impacts are probable. This has the potential to reduce manufacturing and operating costs while improving performance.