Analysis of Composite Three-Layer Honeycomb Structuresin Rocket and Space Technology
Published: 23.03.2026
Authors: Bush A.V., Sviridov A.G., Egorov A.V.
Published in issue: #3(171)/2026
Category: Aviation and Rocket-Space Engineering | Chapter: Design, Construction, Production, Testing, and Operation of Aircraft
The review analyzes domestic and international publications devoted to the application of composite three-layer honeycomb structures in aerospace engineering. The works being reviewed are grouped according to the following directions: application, design, manufacturing technology and testing, computational and experimental studies, optimal parameters, modeling, and analysis. The tasks to be solved in the analyzed works were identified. The influence of structural factors on the load-bearing capacity of composite three-layer structures was demonstrated. Attention was paid to the problem of adhesive bonding of fillers with load-bearing layers. Three-layer structures with different types of fillers, as well as different configurations and materials, were presented. New possible forms of fillers were noted, including rod, discrete, and hybrid ones. The issues of obtaining rational designs, accounting for defects and operational damage, applying non-destructive testing methods and conducting tests were brought up. Information was provided on the use of computer software packages and the modelling of composite three-layer structures using finite element methods.
EDN NDTWVD
References
[1] Trushljakov V.I., Shatrov Ja.T., Lempert D.B., Iordan Ju.V., Zarko V.E. Missile nose cone. Patent RU2581636 C1. 2015. Date of publication: 20.04.2016. Bull. no. 11.
[2] Smerdov A.A., Tairova L.P., Baslyk K.P., Artemiev A.V., Nelyub V.A., Borodulin A.S. Raschetno-eksperimentalnyy analiz dvukh tipov struktur iz ugleplastika dlya krupnogabaritnykh raketno-kosmicheskikh konstruktsiy [Experiment-calculated analysis of two types of CFRP structures for large size rocket-space structures]. Inzhenerny zhurnal: nauka i innovatsii — Engineering Journal: Science and Innovation, 2013, iss. 7. Available at: https://engjournal.bmstu.ru/catalog/machin/rocket/859.html/rocket/859.html
[3] Ivanov E.A., Ikonnikova A.A., Kleshnina I.A., Nagovitsin V.N., Pokhabov A.Yu. Primeneniye konstruktsiy sotovykh paneley v kosmicheskikh apparatakh [Application of honeycomb panel structures in spacecraft]. Inzhenerny zhurnal: nauka i innovatsii — Engineering Journal: Science and Innovation, 2022, iss. 5. Available at: https://engjournal.bmstu.ru/catalog/arse/dcpa/2177.html
[4] Kesselman G.D., Danilov E.N., Nagovitsin V.N., Patraev E.V., Gryaznov V.N. Primeneniye termostatirovannykh sotovykh konstruktsiy v perspektivnykh kosmicheskikh apparatakh i antennykh sistemakh [Using of termostati cally controled honeycomb structures in perspective spacecrafts and antenna systems]. Konstrukcii iz kompozicionnyh materialov — Composite Materials Constructions, 2005, no. 3, pp. 10–13.
[5] Grebnev N.E., Efremov V.A., Kashitsyn A.N., Korotkov A.G., Maksimov S.V., Pospelova O.V. Production method of large three-layer structures from polymer composites. Patent RU2355583 C2. Date of publication: 20.05.2009. Bull. no. 14.
[6] Khmelnitskij A.K., Goncharov K.A., Nasedkin Ju.V., Bush A.V., Shirina O.V. Sandwich Panel. Patent RU2559474 C2. Date of publication: 10.08.2015. Bull. no. 22.
[7] Zamula G.N., Kolesnik K.A. Sposoby povysheniya vesovoy effektivnosti primeneniya kompozitsionnykh konstruktsiy [Weight-saving technique for composite structures]. Obscherossiyskiy nauchno-tekhnicheskiy zhurnal “Polyot” — All-Russian Scientific-Technical Journal “Polyot” (“Flight”), 2018, no. 10, pp. 14–24. EDN: YAJGKL
[8] Kausar A., Ahmad I., Rakha S.A., Eisa M.H., Diallo A. State-of-the-Art of Sandwich Composite Structures: Manufacturing-to-High Performance Applications. J. Compos. Sci., 2023, vol. 7, art. 102. https://doi.org/10.3390/jcs7030102
[9] Gaidachuk V.E., Kondratiev A.V., Kirichenko V.V., Slivinskiy V.I. Optimalnoe proektirovaniye kompozitnykh sotovykh konstruktsiy aviakosmicheskoy tekhniki [Optimal design of composite honeycomb structures for aerospace applications]. Kharkov, 2011, 172 p.
[10] Testoedov N.A. Nagovitsin V.N, Permyakov M.Yu. Primeneniye trekhsloynykh sotovykh konstruktsiy v kosmicheskikh apparatakh [Spacecraft application of three-layer honeycomb structures]. Vestnik SibSAU. Aerospace technologies and control systems, 2016, vol. 17, no. 1, pp. 200–211.
[11] Gorodetskiy M.A., Mikhailovskiy K.V., Reznik S.V. Opredeleniye parametrov trekhsloynykh kompozitnykh paneley dlya konstruktsii platformy kosmicheskikh apparatov distantsionnogo zondirovaniya Zemli [Determining parameters of sandwich composite panels for Earth remote sensing satellite bus]. Kosmicheskaya tekhnika i tekhnologii — Space Engineering and Technology, 2022, no. 1 (36), pp. 36–45.
[12] Kondratiev A.V., Gritskiv L.N. Opredeleniye modulya normalnoy uprugosti sotovogo zapolnitelya pri poperechnom szhatii s uchetom nachalnogo tekhnologicheskogo nesovershenstva folgi [Determination of the modulus of normal elasticity of a honeycomb core under transverse compression, taking into account the initial technological imperfection of the foil]. In: Voprosy proyektirovaniya i proizvodstva konstruktsiy letatelnykh apparatov: sbornik nauchnykh trudov [Issues of design and production of aircraft structures: collection of scientific works]. Vol. 51, no. 4. Kharkov, KhAI, 2007, pp. 131–139.
[13] Wang Z. Recent advances in novel metallic honeycomb structure. Composites Part B: Engineering, 2019, vol. 166, pp. 731–741.
[14] Slivinskiy V.I., Kharchenko M.E., Kondratiev A.V., Gavrilko V.V. Uglesotoplast — legkiy i prochnyy zapolnitel’ trekhsloynoy konstruktsii kosmicheskogo naznacheniya [Carbon fiber reinforced plastic is a lightweight and durable filler for three-layer structures for space applications]. In: Reshetnevskiye chteniya: materialy XVII Mezhdunar. nauchn. konf.: v 2 ch. [Reshetnev Readings: Proceedings of the XVII International Scientific Conf.: in 2 parts]. Krasnoyarsk, 2013, pt. 1, pp. 96–98.
[15] Gaidachuk V.E., Kondratiev A.V., Slivinskiy V.I., Kharchenko M.E. Opredeleniye ratsionalnoy skhemy armirovaniya ugleplasta pri pomoschi MKE-podderzhki [Determination of a rational scheme for reinforcing carbon fiber using FEM support]. Sistemnyye tekhnologii — System Technologies, 2012, issue 2 (79), pp. 3–12.
[16] Stepanov N.V. Razrabotka metodiki proyektirovaniya opornykh uzlov dlya trekhsloynykh sotovykh platform kosmicheskikh apparatov: Dis. … kand. tekhn. nauk: 05.07.02 [Development of a methodology for designing support units for three-layer honeycomb platforms of spacecraft: Diss. ... Cand. Sc. in Engineering]. Obninsk, 2007.
[17] Stepanov N.V., Vymorkov N.V., Krjukov A.M., Osaulenko A.V. Three-ply panel support and method of assembly of said panel with supports. Patent RU2544690 С1. Date of publication: 20.03.2015. Bull. no. 8.
[18] Nilov A.S., Galinskaya O.O., Krasnov V.I. Analiz tekhnologicheskikh osobennostey izgotovleniya trekhsloynoy konstruktsii s prostranstvennym zapolnitelem iz kompozitsionnykh materialov s reaktoplastichnoy matritsey [Analysis of technological features manufacture of three-layer structures with space filler made from composite materials with reactoplastic matrix]. Aerospace Engineering and Technology, 2024, vol. 2, no. 2, pp. 24–51. DOI: 10.52467/2949-401X-2024-2-2-24-51. EDN BQPGTE
[19] Pavlov M.V., Titov S.A., Sviridov A.A., Burdov A.A. Eksperimentalnoe opredeleniye deystvitelnykh prochnostnykh kharakteristik elementov trekhsloynykh paneley vyrezannykh iz agregatov LA [Experimental determination of the actual strength characteristics for the elements of three-layer panels cut from the aircraft assembly]. Journal on Composite Mechanics and Design, 2025, vol. 31, no. 1, pp. 101–116. EDN: DYFKBG
[20] Erasov V.S., Sibayev I.G., Sutubalov A.I. Ispytaniya obraztsov iz trekhsloynykh konstruktsiy s sotovym zapolnitelem [Testing of samples from three-layer structures with honeycomb filler]. Trudy VIAM — Proceedings of VIAM, 2025, no. 10, pp. 133–155. dx.doi.org/ 10.18577/2307-6046-2025-0-10-133-155
[21] Nowakowski D. et al. Examination of honeycomb core compliance in sandwich structure. Fatigue of Aircraft Structures, 2019, vol. 2019, no. 11, pp. 19–27.
[22] Jedral A. Review of testing methods dedicated for sandwich structures with honeycomb core. Transactions on Aerospace Research, 2018, vol. 3, pр. 7–20. https://doi.org/10.2478/tar-2019-0006
[23] Widagdo D., Kuswoyo A., Nurpratama O.T., Hadi B.K. Experimental flatwise tensile strength dataset of carbon fibre reinforced plastic sandwich panels with different core material preparations. 2019. Data in brief 28 (2020) 105055. https://doi.org/10.1016/j.dib.2019.105055
[24] Abbadi A., Tixier C., Gilgert J., Azari Z. Experimental study on the fatigue behavior of honeycomb sandwich panels with artificial defects. Composite Structures, 2015, vol. 120, pp. 394–405. https://doi.org/10.1016/j.compstruct.2014.10.020
[25] Sun Z., Shi Sh., Guo X., Hu X., Chen H. On compressive properties of composite sandwich structures with grid reinforced honeycomb core. Composites Part B: Engineering, 2016, vol. 94, pp. 245–252. https://doi.org/10.1016/j.compositesb.2016.03.054
[26] Kim G., Sterkenburg R., Waterloo T. Investigating the effects of fluid intrusion on Nomex honeycomb sandwich structures with carbon fiber facesheets. Composite Structures, 2018, vol. 206, pp. 535–549. https://doi.org/10.1016/j.compstruct.2018.08.054
[27] Laplante G. Detection of water ingress in composite sandwich structures: A magnetic resonance approach. NDT & E International, 2005, vol. 38, no. 6, pp. 501–507. https://doi.org/10.1016/J.NDTEINT.2005.01.006
[28] Ustarkhanov O.M., Muselemov Kh.M., Kiayvov U.A., Ustarkhanov T.O. Opredeleniye ratsionalnykh form sotovogo zapolnitelya dlya trekhsloynoy balki pri deystvii staticheskoy nagruzki [Definition of rational forms honeycomb core for sandwich beams under static loading]. Sovremennaya nauka: aktualnyye problemy i puti ikh resheniya (Modern Science: Current Problems and Solutions), 2014, no. 12, pp. 46–51. EDN: SYDCJD
[29] Xiong J., Du Y., Mousanezhad D., Asl M.E., Norato J., Vaziri A. Sandwich structures with prismatic and foam cores: A review. Advanced Engineering Materials, 2019, vol. 21, no. 1, paper 1800036. DOI: 10.1002/adem.201800036
[30] He R., Zhao C., Wang G., Zhang Z., Li F. Finite Element Analysis of in-plane compression of aluminum alloy honeycomb panels. Structures, 2023, vol. 49, pp. 267–280.
[31] Basharov E.A. Raschet optimal’nykh konstruktivnykh parametrov i primeneniye v aerokosmicheskikh konstruktsiyakh trekhsloynykh sotovykh paneley iz polimernykh kompozitsionnykh materialov [Computation of optimal design parameters and introduction of the three-layer honeycomb panels made from polymer composite materials in the aerospace systems]. Inzhenerny zhurnal: nauka i innovatsii — Engineering Journal: Science and Innovation, 2024, iss. 10. EDN JOFBHO
[32] Mousavi Safavi Seyed Mohammad. Modelirovaniye i proyektirovaniye fermennykh zapolniteley trekhsloynykh konstruktsiy aviakosmicheskogo naznacheniya: Dis. … kand. tekhn. nauk: 2.5.13 [Modeling and design of truss cores of three-layer structures for aerospace applications: Diss. ... Cand. Sc. in Engineering]. Kazan, 2022, 141 p.
[33] Abdullin I.N. Ratsionalnoe proektirovaniye trekhsloynykh konstruktsiy so sterzhnevym zapolnitelem: Dis. … kand. tekhn. nauk: 05.07.02 [Rational design of three-layer structures with rod filler: Diss. ... Cand. Sc. in Engineering]. Kazan, 2016, 125 p.
[34] Kaman M.O., Solmaz M.Y., Turan K. Experimental and numerical analysis of critical buckling load of honeycomb sandwich panels. Journal of composite materials, 2010, vol. 44, no. 24, pp. 2819–2831. https://doi.org/10.1177/0021998310371541
[35] Akkus H., Duzcukoglu H., Sahin O.S. Experimental research and use of finite elements method on mechanical behaviors of honeycomb structures assembled with epoxy-based adhesives reinforced with nanoparticles. Journal of Mechanical Science and Technology, 2017, vol. 31 (1), pp. 165–170. https://doi.org/10.1007/s12206-016-1216-0
[36] Jang J., Jeong S., Oh D., Cho Je-H., Noh J. Test and evaluation procedure of foam core materials for composite ships. Journal of the Korean Society of Marine Environment and Safety, 2020, vol. 26 (3), pp. 103–119. DOI: 10.7837/kosomes.2020.26.3.286
[37] Nurul Lailarul M., Taufiq Satrio Nurtiasto, Rezky Agung Pratomo, Afid Nugroho, Anis Mutiara Balqis. Studi sifat mekanik komposit sandwich divinycell foam dengan metode vacuum assisted resin infusion (vari) untuk float pesawat amfibi. Conference: Prosiding Seminar Nasional Riset Teknologi Terapan, 2021. Indonesia. e-ISSN:2747-1217
[38] Djemaoune Y., Krstic B., Radulovic D., Rasic S., Dodic M. Numerical investigation of open-hole damaged NomexTM honeycomb panel under three-point bending load. Scientific Technical Review, 2021, vol. 71, no. 2, pp. 14–18. DOI: 10.5937/str2102014D
[39] Evstafiev V.A. Konstruirovaniye kosmicheskikh apparatov [Design of spacecraft]. Part 1. St. Petersburg, BSTU "VOENMEKh" named after D.F. Ustinov, 2018.
[40] Butukuri R.R., Bheemreddy V., Chandrashekhara K., Berkel T.R., Rupel K. Evaluation of skin-core adhesion bond of out-of-autoclave honeycomb sandwich structures. Journal of Reinforced Plastics and Composites, 2012, vol. 31, no. 5, pp. 331–339. DOI: 10.1177/0731684412437267
[41] Malysheva G.V., Grashchenkov D.V., Guzeva T.A. Otsenka tekhnologichnosti ispol’zovaniya kleyev i kleyevykh prepregov pri izgotovlenii trekhsloynykh paneley [Evaluation of technological use efficiency of adhesives and glue prepregs in the manufacture of three-layer panels]. Aviatsionnyye materialy i tekhnologii (Aviation Materials and Technology), 2018, no. 4 (53), pp. 26–30. DOI: 10/18577/2071-9140-2018-0-4-26-30
[42] Pavlova S.A. Analiz kontaktnogo vzaimodeystviya polimernogo sotovogo zapolnitelya s nesushchimi sloyami v trekhsloynykh konstruktsiyakh [Analysis of contact interaction of polymer honeycomb core and CFRP base layers in sandwich-core constructions]. Vestnik Samarskogo universiteta. Aerokosmicheskaya tekhnika, tekhnologii i mashinostroenie — VESTNIK of Samara University. Aerospace and Mechanical Engineering, 2021, vol. 20, no. 1, pp. 87–96. EDN XLOEFT
[43] Grove S.M., Popham E., Miles M.E. An investigation of the skin/core bond in honeycomb sandwich structures using statistical experimentation techniques. Composites Part A: Applied Science and Manufacturing, 2006, vol. 37, no. 5, pp. 804–812. DOI: 10.1016/j.compositesa.2005.07.005
[44] Rion J., Leterrier Y., Månson J.-A.E. Prediction of the adhesive fillet size for skin to honeycomb core bonding in ultra-light sandwich structures. Composites Part A: Applied Science and Manufacturing, 2008, vol. 39, no. 9, pp. 1547–1555. DOI: 10.1016/j.compositesa.2008.05.022
[45] Vishtalov R.I., Muselemov H.M., Ustarkhanov O.M. Opredeleniye privedennykh kharakteristik sotovykh zapolniteley razlichnykh form [The definition of the given characteristics of honeycomb fillers of the different shapes]. Vestnik Dagestanskogo gos. tekhn. un-ta. Tekhnicheskiye nauki — Herald of Daghestan State Technical University. Technical Sciences, 2016, vol. 42, no. 3, pp. 155–166. DOI: 10.21822/2073-6185-2016-42-3-155-166
[46] Ivañez I., Sanchez-Saez S. Numerical modelling of the low-velocity impact response of composite sandwich beams with honeycomb core. Composites Structures, 2013, vol. 106, pp. 716–727.
[47] Buitrago B.L., Santiuste C., Sánchez-Sáez S., Barbero E., Navarro C. Modelling of composite sandwich structures with honeycomb core subjected to high-velocity impact. Composites Structures, 2010, vol. 92, pp. 2090–2096.
[48] Medvedskiy A.L., Martirosov M.I., Khomchenko A.V., Dedova D.V. Chislennyy analiz povedeniya trekhsloynoy paneli s sotovym zapolnitelem pri nalichii defektov pod deystviyem dinamicheskoy nagruzki [Numerical analysis of the behavior of a three-layer honeycomb panel with interlayer defects under action of dynamic load]. Stroitelnaya mekhanika inzhenernykh konstruktsiy — Structural Mechanics of Engineering Constructions and Buildings, 2021, no. 17 (4), pp. 357–365. http://dx.doi.org/10.22363/1815-5235-2021-17-4-357-365
[49] Pavlov M.V. Metodiki opredeleniya raschetnykh kharakteristik trekhsloynykh materialov dlya obespecheniya staticheskoy prochnosti konstruktsii letatel’-nogo apparata. Dis. … kand. tekhn. nauk [Methods for determining the design characteristics of three-layer materials to ensure the static strength of an aircraft structure. Diss. … Cand. Sc. in Engineering]. Zhukovsky, 2025, 184 p.
[50] Wang Z., Li Z., Zhou W., Hui D. On the influence of structural defects for honeycomb structure. Composites Part B: Engineering, 2018, vol. 142, pp. 183–192.
[51] Chen D.H., Ozaki S. Stress concentration due to defects in a honeycomb structure. Composites Structures, 2009, vol. 89, pp. 52–59.
[52] Rizov V., Shipsha A., Zenkert D. Indentation study of foam core sandwich composite panels. Composite Structures, 2005, vol. 69, no. 1, c. 95–102.
[53] Keselman G.D., Zimin I.I., Danilov E.N., Patraev E.V., Gryaznov V.N. Raschet na prochnost’ trekhsloynoy konstruktsii i zakladnykh elementov [Calculation on strength of three-layered design and fitted elements]. Konstruktsii iz kompozitsionnykh materialov — Composite Materials Constructions, 2006, no. 1, pp. 6–15. EDN: KBEJYL
[54] Volkov A.N. Modelirovaniye i raschet slozhnykh trekhsloynykh konstruktsiy s diskretnym zapolnitelem: Dis. … kand. tekhn. nauk: 2.5.14 [Modeling and calculation of complex three-layer structures with discrete filler: Diss. ... Cand. Sc. in Engineering]. Moscow, MAI, 2023.