Topology optimization design for maximizing stiffness in three-dimensional high-performance sandwich panels

Sandwich panels in engineering applications are typically subjected to varied support and loading scenarios. However, traditional core designs based on predefined geometries often exhibit significant performance deterioration when service conditions shift. This study employs a parametric level set–based topology optimization method to maximize core stiffness under multiple representative conditions. Numerical results demonstrate that both support conditions and loading patterns have a decisive influence on global stiffness; the four-edge fixed configuration with concentrated loading achieves the highest stiffness, while the four-corner supported configuration with uniformly distributed loading exhibits the lowest stiffness due to restricted load-transfer efficiency. Unlike studies limited to comparing fixed topological families, the proposed framework automatically generates a synthesized honeycomb-like structure (SHLS) with adaptive load-transmission paths under multi-condition. Three-point bending simulations and experiments on selective laser melting (SLM)-fabricated AlSi10 Mg specimens reveal that, at identical core thickness, the proposed core achieves the highest specific stiffness and the highest specific energy absorption (SEA). Compared with traditional honeycomb-like structure (THLS) and honeycomb structure (HS), the specific stiffness of the SHLS is enhanced by up to 27% and 5%, respectively. Numerical simulations and experimental results exhibit high consistency throughout the loading process, confirming the reliability of the modeling framework.