We investigate the elastic behaviour of periodic hexagonal honeycombs over a wide range of relative densities and cell geometries, using both analytical and numerical approaches. Previous modelling approaches are reviewed and their limitations identified. More accurate estimates of all nine elastic constants are obtained by modifying the analysis of Gibson and Ashby (1997) to account for the nodes at the intersection of the vertical and inclined members. The effect of the nodes becomes significant at high relative densities. We then compare the new analytical equations with previous analytical models, with a numerical analysis based on a computational homogenization technique and with data for rubber honeycombs over a wide range of relative densities and cell geometries. The comparisons show that both the new analytical equations and numerical solutions give a remarkably good description of the data. The results provide new insights into understanding the mechanics of honeycombs and designing new cellular materials in the future.

Additive manufacturing is a fabrication technology that is rapidly revolutionizing the manufacturing and construction sectors. In this paper, a review of various prototyping technologies for printing cementitious materials and selected 3D printing techniques are presented in detail. Benchmark examples are provided to compare three well-known printing techniques; inkjet printing (binder jetting), selected laser sintering (SLS), and extrusion printing (extrusion based process). A comprehensive search in the literature was conducted to identify various mix designs that could be employed when printing cementitious materials. Aspects of concrete mix design are described, and some new experiments are conducted to analyse the printability of new mixes by the authors. Future research in the area of the rheology of cementitious materials and its relationship with the structural performance of finished concretes are highlighted.

Additive manufacturing technologies offer new ways to fabricate cellular materials with composite cell walls, mimicking the structure and mechanical properties of woods. However, materials limitations and a lack of design tools have confined the usefulness of 3D printed cellular materials. We develop new carbon fiber reinforced, epoxy inks for 3D printing which result in printed materials with longitudinal Young's modulus up to 57 GPa (exceeding the longitudinal modulus of wood cell wall material). To guide the design of hierarchical cellular materials, we developed a parameterized, multi-scale, finite element model. Computational homogenization based on finite element simulations at multiple length scales is employed to obtain the elastic properties of the material at multiple length scales. Parameters affecting the elastic response of cellular composites, such as the volume fraction, orientation distribution, and aspect ratio of fibers within the cell walls as well as the cell geometry and relative density are included in the model. To validate the model, experiments are conducted on both solid carbon fiber/epoxy composites and cellular structures made from them, showing excellent agreement with computational multi-scale model predictions, both at the cell-wall and at the cellular-structure levels. Using the model, cellular structures are designed and experimentally shown to achieve a specific stiffness nearly as high as that observed in balsa wood. The good agreement between the multi-scale model predictions and experimental data provides confidence in the practical utility of this model as a tool for designing novel 3D cellular composites with unprecedented specific elastic properties.

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