Sandwich composites are widely used in aerospace materials thanks to their low weight and high strength properties. The purpose of this study is to observe the effects of polyurethane foam filling on honeycomb core structures produced by additive manufacturing in terms of mechanical strength and moisture absorption properties. Within the scope of the study, honeycomb structures were produced by a 3D printer using polylactic acid (PLA) filament. Then, the honeycomb core was filled with polyurethane foam, which is supplied in liquid form. After the core material was given its final form, it was combined with an epoxy and carbon fibre facesheet material using the vacuum infusion technique. After the sandwich composite production was completed, in-plane compression, three-point bending, shear, and moisture absorption tests were applied. The polyurethane foam filling greatly increased the mechanical strength, but slightly more moisture absorption occurred in this structure compared to a hollow honeycomb structure.

A design and manufacturing method is described for creating a motor tendon–actuated soft foam robot. The method uses a castable, light, and easily compressible open-cell polyurethane foam, producing a structure capable of large (~70% strain) deformations while requiring low torques to operate (<0.2 N·m). The soft robot can change shape, by compressing and folding, allowing for complex locomotion with only two actuators. Achievable motions include forward locomotion at 13 mm/s (4.3% of body length per second), turning at 9◦/s, and end-over-end flipping. Hard components, such as motors, are loosely sutured into cavities after molding. This reduces unwanted stiffening of the soft body. This work is the first demonstration of a soft open-cell foam robot locomoting with motor tendon actuators. The manufacturing method is rapid (~30 min per mold), inexpensive (under $3 per robot for the structural foam), and flexible, and will allow a variety of soft foam robotic devices to be produced.