An integrated additive manufacturing method for foam sandwich structures, foam sandwich structures

Abstract

This invention belongs to the field of additive manufacturing technology, specifically relating to an integrated additive manufacturing method for foam sandwich structures and the foam sandwich structure itself. The method includes: determining the printing parameters of a 3D printer, wherein the 3D printer includes a first nozzle for printing the core material into a core, and a second nozzle for printing the panel material (including the core material and a foaming material mixed in the core material) into a panel. The printing parameters include the printing paths of the first and second nozzles. The 3D printer then prints and deposits layers according to the printing parameters until the foam sandwich structure is completed. This method eliminates the need for bonding, allowing for integrated molding of the foam sandwich structure; it also eliminates the need for molds, enabling the fabrication of complex foam sandwich structures, significantly reducing production costs and improving production efficiency. The foam sandwich structure prepared by this method is characterized by its lightweight and high structural rigidity.

Description

Technical Field

[0001] This invention belongs to the field of additive manufacturing technology, specifically relating to an integrated additive manufacturing method for a foam sandwich structure and the foam sandwich structure. Background Technology

[0002] Continuous fiber composites, due to their high specific strength, high specific modulus, and designability, are widely used in aerospace, shipbuilding, automotive, and energy fields. Sandwich structures, as a novel structural form, have gained significant attention in recent years due to their lightweight and functional designability. Additive manufacturing technology is an emerging molding process based on the discrete-stacking principle. Because additive manufacturing can efficiently and cost-effectively mold complex parts while providing a high degree of design freedom, it is increasingly being applied to the molding of continuous fiber reinforced polymer matrix composites. Compared to traditional sandwich bonding molding techniques, additive manufacturing for composite materials offers advantages such as mold-free operation, flexible processes, and shorter development cycles, enabling the integrated molding of complex sandwich structures with superior performance that traditional methods cannot achieve.

[0003] Fused Deposition Modeling (FDM) is one of the most mature additive manufacturing technologies. It utilizes the heat-melting and adhesive properties of thermoplastic materials to build up layers under system control, based on data obtained from slicing 3D CAD models.

[0004] Traditional composite sandwich structure manufacturing processes involve manufacturing the panels and core separately and then bonding them together. This process has disadvantages such as poor material structure rigidity, complex manufacturing process, and low design freedom.

[0005] Therefore, existing technologies still need to be improved and developed. Summary of the Invention

[0006] In view of the shortcomings of the prior art, the present invention aims to provide an integrated additive manufacturing method and foam sandwich structure, which aims to solve the technical problems of the traditional composite material sandwich structure manufacturing process, which involves manufacturing the panel and the core separately and then bonding them together. This process is complex and results in poor stiffness of the sandwich structure.

[0007] This invention provides an integrated additive manufacturing method for a foam sandwich structure, the foam sandwich structure including a panel and a core, the panel including an upper panel and a lower panel, and the core located between the upper panel and the lower panel;

[0008] The integrated additive manufacturing method includes the following steps:

[0009] Provide panel printing materials and sandwich printing materials, wherein the sandwich printing material includes a sandwich main material and a foaming material mixed in the sandwich main material;

[0010] The printing parameters of the 3D printer are determined. The 3D printer includes a first nozzle for printing the sandwich printing material into the sandwich and a second nozzle for printing the panel printing material into the panel. The printing parameters include the printing paths of the first nozzle and the second nozzle.

[0011] The 3D printer prints and stacks layers one by one according to the printing parameters until the foam sandwich structure is printed.

[0012] Optionally, the panel printing material includes a continuous fiber-reinforced material; and / or,

[0013] The method also includes printing continuous fiber reinforcement material during the printing process of the sandwich core.

[0014] Optionally, the continuous fiber reinforced material includes at least one of continuous carbon fiber reinforced material, continuous glass fiber reinforced material, and continuous aramid fiber reinforced material; and / or,

[0015] The continuous fiber reinforced material is a pre-impregnated continuous fiber reinforced material.

[0016] Optionally, the panel printing material and the core comprise the same continuous fiber reinforcement material;

[0017] The printing of continuous fiber reinforcement material during the printing process of the sandwich core includes:

[0018] During the printing process of at least a portion of the core by the first printhead, the first printhead is paused so that the panel printing material can be printed onto the at least a portion of the core by the second printhead.

[0019] Optionally, the printing path of the second nozzle in at least some layers of the core is an interlaced line.

[0020] Optionally, during the printing process of at least some layers of the core by the first printhead, for each of the at least some layers of the core, after switching to the second printhead, the panel printing material is printed onto the layer in one go through the second printhead.

[0021] Optionally, the method further includes: removing the panel printing material printed outside the sandwich in each of at least some of the layers of the sandwich.

[0022] Optionally, the panel printing material also includes at least one of polylactic acid filament, thermoplastic polyurethane elastomer filament, polyethylene terephthalate-1,4-cyclohexanediol filament, polyamide filament, and polycarbonate filament.

[0023] The core material includes one of polylactic acid and thermoplastic polyurethane elastomer; and / or,

[0024] The foaming material includes foamed microspheres.

[0025] Optionally, the printing parameters of the 3D printer include at least one of the following: the height of each printed layer, the width of the trace, the thickness of the outer wall of the model's side, the filling method inside the model, the filling density inside the model, the printing temperature, the printing platform temperature, the material flow rate, the retraction speed, the retraction distance, the printing speed, the fan speed, the support type, and the attachment type of the model on the printing platform.

[0026] Optionally, during the printing process of the first nozzle in the 3D printer, the printing temperature of the first nozzle is adjusted in a preset manner according to the printing parameters.

[0027] Optionally, determining the printing parameters of the 3D printer includes:

[0028] Obtain the printing path of the panel, which is designed based on the geometric dimensions of the panel;

[0029] The printing path of the core is obtained by importing the three-dimensional model of the core into 3D slicing software for slicing processing. The three-dimensional model is designed according to the geometric dimensions of the core.

[0030] Optionally, when the 3D printer is printing layer by layer according to the printing parameters, it can switch the printing nozzle by adjusting the height of at least one of the first nozzle and the second nozzle, depending on the printing material.

[0031] Optionally, when the 3D printer is printing and stacking layers according to the printing parameters, it keeps the height of one of the first and second nozzles fixed, and switches the printing nozzle when the height of the other nozzle is higher or lower than the height of the nozzle with the fixed height.

[0032] The present invention also provides a foam sandwich structure comprising the foam sandwich structure manufactured by the above method.

[0033] Beneficial Effects: This embodiment provides an integrated additive manufacturing method for foam sandwich structures, which differs from traditional composite foam sandwich structure manufacturing processes that involve separately manufacturing the panel and foam core and then bonding them, or injecting the foam core into the panel after manufacturing the panel. This method eliminates the need for bonding and can integrally prepare the foam sandwich structure, thereby reducing production costs and improving production efficiency. Furthermore, in existing processes where the foam core is directly injected, the uniformity of foam expansion is difficult to control. This embodiment forms the foam core through printing, facilitating the design and control of the printing parameters, enabling more precise control of the foam core's mechanical properties and providing greater design freedom. Moreover, this method eliminates the need for molds and can also prepare complex sandwich structures, further significantly reducing production costs and improving production efficiency. Attached Figure Description

[0034] Figure 1 This is a schematic diagram of the foam sandwich structure in a specific embodiment of the present invention;

[0035] Figure 2 This is a schematic diagram of a printing path for a foam sandwich structure in a specific embodiment of the present invention;

[0036] Figure 3 This is a schematic flowchart of the integrated additive manufacturing method for foam sandwich structures in a specific embodiment of the present invention;

[0037] Figure 4 This is a schematic diagram of another printing path for the foam sandwich structure in a specific embodiment of the present invention. Detailed Implementation

[0038] This invention provides an integrated additive manufacturing method for foam sandwich structures. To make the objectives, technical solutions, and effects of this invention clearer and more explicit, the invention is further described in detail below. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.

[0039] This invention provides an integrated additive manufacturing method for a foam sandwich structure, wherein the foam sandwich structure includes a panel and a core, the panel includes an upper panel and a lower panel, and the core is located between the upper panel and the lower panel;

[0040] The integrated additive manufacturing method includes the following steps:

[0041] S1. Provide panel printing material and sandwich printing material, wherein the sandwich printing material includes a sandwich main material and a foaming material mixed in the sandwich main material;

[0042] S2. Determine the printing parameters of the 3D printer, wherein the 3D printer includes a first nozzle for printing the sandwich printing material into the sandwich, and a second nozzle for printing the panel printing material into the panel;

[0043] The S3 3D printer prints and stacks layers according to the printing parameters until the foam sandwich structure is printed.

[0044] The printing parameters include the printing paths of the first and second printheads. The printing paths of the first and second printheads can be determined by designing the geometric dimensions of the panel and core according to the required foam sandwich structure, and then determining the printing paths of the panel and core based on these designed geometric dimensions.

[0045] This embodiment provides an integrated additive manufacturing method for foam sandwich structures, which differs from traditional composite foam sandwich structure manufacturing processes that involve separately manufacturing the panel and foam core and then bonding them, or injecting the foam core into the panel after manufacturing the panel. This method eliminates the need for bonding and can integrally prepare the sandwich structure, thereby reducing production costs and improving production efficiency. Furthermore, in existing processes where the foam core is directly injected, the uniformity of foam expansion is difficult to control. This embodiment forms the foam core through printing, facilitating the design and control of the printing parameters, enabling more precise control of the foam core's mechanical properties and providing greater design freedom. Moreover, this method eliminates the need for molds and can also prepare complex sandwich structures, further significantly reducing production costs and improving production efficiency.

[0046] In one example, the panel printing material includes a continuous fiber reinforcement. Including continuous fiber reinforcement helps improve the overall structural performance of the panel, such as specific stiffness and specific strength, and also enhances the panel's designability. Optionally, the panel printing material also includes at least one of polylactic acid (PLA) filaments, TPU (thermoplastic polyurethane elastomer) filaments, PETG (polyethylene terephthalate-1,4-cyclohexanediol) filaments, PA (polyamide) filaments, and PC (polycarbonate) filaments. Further, the PLA filaments can be PLA filaments with a diameter of 1.75 mm. Optionally, the continuous fiber reinforcement can be pre-impregnated. The continuous fiber reinforcement and other materials in the panel printing material are fed into a second nozzle, heated and melted by a heater in the second nozzle, and then printed onto a substrate by the second nozzle, where they solidify and take shape.

[0047] In one example, the sandwich printing material includes a sandwich master material and a foam material mixed in the sandwich master material. The sandwich master material may include at least one of polylactic acid and thermoplastic polyurethane elastomer. The foam material may include foamed microspheres. The sandwich master material and the foam material are fed into a first printhead, heated by a heater in the first printhead, and then printed onto a substrate.

[0048] Optionally, the printing parameters of the 3D printer can be adjusted according to the properties of the printing material. For example, during the printing process, changes in temperature will cause changes in the foaming rate of the foaming material, which in turn will cause changes in the extrusion flow rate of the first nozzle. Therefore, by controlling the temperature change, the extrusion flow rate of the sandwich printing material can be controlled, achieving precise control over the mechanical properties of the sandwich printing material.

[0049] Optionally, the printing temperature of the sandwich printing material can be between 180 and 250 degrees Celsius. From 180 to 230 degrees Celsius, the foaming rate of the foam material gradually increases with increasing temperature. From 230 to 250 degrees Celsius, the foaming rate gradually decreases with increasing temperature. The foam material exhibits good mechanical properties at 180 degrees Celsius, which decrease as the foaming rate increases. Therefore, during the printing process of the sandwich printing material, the printing temperature on different printing paths can be adjusted according to the performance requirements of the sandwich core to achieve precise control over the mechanical properties of the foam core.

[0050] Optionally, during the printing process of the core, the addition of continuous fiber reinforcement material can further improve the physical properties of the core. The continuous fiber reinforcement material included in the core can be the same as or different from the continuous fiber reinforcement material in the panel. The nozzle for printing the continuous fiber reinforcement material into the core can be a third nozzle in the 3D printer. Alternatively, the continuous fiber reinforcement material included in the core can be the same as the continuous fiber reinforcement material in the panel. When printing the continuous fiber reinforcement material in the core, the panel printing material printed by the second nozzle is reused and printed into the core. Specifically, the printing path of the second nozzle includes not only the printing path for printing the panel printing material into the panel, but also the printing path for printing the panel printing material into the core. During the printing process of at least some layers of the core by the first nozzle, the first nozzle is paused and switched to the second nozzle to print the panel printing material into the at least some layers of the core through the second nozzle. Optionally, the continuous fiber reinforcement material contained in the core may be different from the continuous fiber reinforcement material in the panel. The reused second nozzle prints the panel printing material when printing the panel, and switches to print another continuous fiber reinforcement material into the core when printing the core.

[0051] Optionally, the printing paths of the continuous fiber reinforcement material printed in at least some layers of the core can be multiple parallel paths within that layer; or, they can be multiple intersecting paths within that layer, such as an intersecting grid pattern, which can better improve the performance of the core. During the printing process of at least some layers of the core by the first nozzle, for each of the at least some layers of the core, after switching to the second nozzle, the panel printing material is printed onto the layer in one go through the second nozzle. Figure 4 As shown, Figure 4 This is a schematic diagram of the printing path of the continuous fiber reinforcement material in one layer of the sandwich core. Figure 4 Path 42 is a schematic diagram of the printing path of the first nozzle, and path 41 is a schematic diagram of the printing path of the continuous fiber reinforcement material in the core. Considering the characteristics of the continuous fiber reinforcement material, the printing of this layer of continuous fiber reinforcement material in the core is preferably completed in one step. During the one-step printing process, the turning point of the printing path of the continuous fiber reinforcement material can be inside or outside the core. Figure 4 The turning point of the path shown is outside the core. In the case where the turning point is outside the core, the continuous fiber reinforcement material extending beyond the core is removed once after the core is printed.

[0052] The foam sandwich structure prepared by the method in this embodiment uses a foamed material for the core printing and is designed accordingly. Therefore, the overall foam sandwich structure is lightweight and has good structural rigidity. Furthermore, customized requirements can be achieved through further structural design of the core. That is, the structure of the core is not limited to a regularly arranged diamond-shaped through-hole structure; it can be customized according to specific needs. The core structure in this embodiment has a high degree of design freedom.

[0053] Optionally, the continuous fiber reinforced material includes at least one selected from continuous carbon fiber reinforced material, continuous glass fiber reinforced material, and continuous aramid fiber reinforced material. Further, the continuous carbon fiber reinforced material is a pre-impregnated continuous fiber reinforced material.

[0054] Optionally, the continuous fiber reinforcement material is a continuous carbon fiber reinforcement material, and the main material of the panel is polylactic acid wire.

[0055] Optionally, the printing parameters of the 3D printer include at least one of the following: the height of each printed layer, the width of the filament, the thickness of the outer wall of the model's side, the infill method of the model's interior, the infill density of the model's interior, the printing temperature, the printing platform temperature, the material flow rate, the filament retraction speed, the filament retraction distance, the printing speed (referring to the nozzle's movement speed), the fan speed, the support type (referring to the support method that can be selected when printing a model with suspended parts), and the attachment type of the model on the printing platform.

[0056] In one example, the printing parameters of the 3D printer are set as follows: the height of each layer is 0.2 mm, the line width is 0.4 mm, the thickness of the outer wall of the model side is 1 mm, the infill method inside the model is straight, the infill density inside the model is 100%, the printing temperature is 210℃ for the panel and 230℃ for the core material, the printing platform temperature is 60℃, the flow rate is 100% for the panel and 45% for the core material, the retraction speed is 0, the retraction distance is 0, the printing speed is 25 mm / s for the panel and 40 mm / s for the core material, the fan speed is 100%, the support type is none, and the attachment type of the model on the printing platform is none.

[0057] Optionally, the printing paths for the panel and the core can be obtained by writing the printing paths for the panel and the core respectively using MATLAB software based on the designed geometric dimensions of the panel and the core.

[0058] Optionally, in this embodiment, based on the designed geometric dimensions of the foam sandwich structure, the printing path of the foam sandwich structure is written using MATLAB software to obtain the number of layers of the model and the printing path of each layer.

[0059] Optionally, the printing paths for the panel and the core can be obtained by writing the printing path of the panel using MATLAB software based on the designed geometric dimensions of the panel; and by drawing a three-dimensional model of the core using 3D CAD software based on the designed geometric dimensions of the core, and importing the three-dimensional model into the 3D slicing software Aura in STL format for slicing processing to obtain the printing path of the core.

[0060] Optionally, when the 3D printer is printing layer by layer according to the printing parameters, it can switch the printing nozzle by adjusting the height of at least one of the first and second nozzles, depending on the printing material. In one example, when the 3D printer is printing layer by layer according to the printing parameters, it keeps the height of one of the first and second nozzles fixed, and switches the printing nozzle when the height of the other nozzle is higher or lower than the height of the fixed nozzle. For example, the 3D printer may be fixed to printing with a lower-height nozzle, pausing printing with a higher-height nozzle. When controlling the first and second nozzles, the height of the second nozzle is kept constant. When the height of the first nozzle is adjusted to be lower than that of the second nozzle, the second nozzle pauses printing and the printer switches to the first nozzle to start printing; when the height of the first nozzle is adjusted to be higher than that of the second nozzle, the printing with the first nozzle stops and the printer switches back to the first nozzle after the height adjustment.

[0061] The present invention will be further described below through specific embodiments.

[0062] Combination Figure 1-3 As shown, the foam sandwich structure to be manufactured in this embodiment includes a panel 11 and a core 12. The panel includes an upper panel and a lower panel, and the core is located between the upper panel and the lower panel. The panel has geometric dimensions of 70mm in length, 26mm in width, and 1mm in height, and the core has geometric dimensions of 70mm in length, 26mm in width, and 10mm in height. The core has a regularly arranged diamond-shaped through-hole structure.

[0063] The integrated additive manufacturing method for foam sandwich structures in this embodiment includes the following steps:

[0064] Step 1: Provide panel printing material (which is heated and melted by heater 2 in the second nozzle 1 of the printer during printing and then flows out from the second nozzle 1) and core printing material (which is heated and melted by heater 4 in the first nozzle 3 of the printer during printing and then flows out from the first nozzle 3 of the printer). The panel printing material is composed of polylactic acid filament 5 and continuous carbon fiber reinforcement mixed in the polylactic acid filament 5. The continuous carbon fiber reinforcement is pre-impregnated continuous carbon fiber reinforcement 6. The core printing material is composed of polylactic acid filament and foaming material 7 mixed in the polylactic acid filament.

[0065] Step 2: Determine the 3D printer printing parameters based on the panel printing material and the core printing material: Layer height is 0.2mm, filament width is 0.4mm, outer wall thickness is 1mm, infill method is straight lines, infill density is 100%, printing temperature is 210℃ for the panel, 230℃ for the core material, and 60℃ for the printing platform; material flow rate is 100% for the panel and 45% for the core material; filament retraction speed is 0; filament retraction distance is 0; printing speed is 25mm / s for the panel and 40mm / s for the core; fan speed is 100%; support type is none; model attachment type on the printing platform is none. The printing temperature is provided by a heater.

[0066] Step 3: Design the geometric dimensions of the panel and the core according to the required foam sandwich structure;

[0067] Step 4: Based on the designed panel geometry, the printing path of the panel is written using MATLAB software to obtain the panel printing path; based on the designed core geometry, a 3D model of the core is drawn using 3D CAD software, and the 3D model is imported into the 3D slicing software Aura in STL format for slicing to obtain the core printing path. The printing paths of the panel and the core are combined to obtain the overall printing information (see...). Figure 2(as shown);

[0068] Step 5: The 3D printer prints and stacks layers one by one according to the overall printing information until the continuous fiber-reinforced foam sandwich structure is printed.

[0069] In summary, this invention provides an integrated additive manufacturing method for foam sandwich structures. Unlike traditional composite foam sandwich structures where panels and cores are manufactured separately and then bonded together, or where foam cores are injected into the panels after they are manufactured, this invention eliminates the need for bonding, allowing for integrated molding of the sandwich structure. This reduces production costs and improves efficiency. Furthermore, in existing processes where foam cores are directly injected, controlling the uniformity of foam expansion is difficult. This invention forms the foam core through printing, facilitating the design and control of printing parameters, enabling more precise control over the mechanical properties of the foam core and providing greater design freedom. This method also eliminates the need for molds, allowing for the fabrication of complex sandwich structures, further reducing production costs and improving efficiency. The sandwich structure prepared by this invention is characterized by its lightweight and high structural rigidity.

[0070] It should be understood that the application of the present invention is not limited to the examples above. Those skilled in the art can make improvements or modifications based on the above description, and all such improvements and modifications should fall within the protection scope of the appended claims.

Claims

1. An integrated additive manufacturing method for a foam sandwich structure, characterized in that, The foam sandwich structure includes a panel and a core, the panel includes an upper panel and a lower panel, and the core is located between the upper panel and the lower panel; The integrated additive manufacturing method includes the following steps: Provide panel printing materials and sandwich printing materials, wherein the sandwich printing material includes a sandwich main material and a foaming material mixed in the sandwich main material; The printing parameters of the 3D printer are determined. The 3D printer includes a first nozzle for printing the sandwich printing material into the sandwich and a second nozzle for printing the panel printing material into the panel. The printing parameters include the printing path of the first nozzle and the printing path of the second nozzle. The 3D printer prints and stacks layers according to the printing parameters until the foam sandwich structure is printed. The method also includes printing continuous fiber reinforcement material during the printing process of the sandwich core; The continuous fiber reinforcement material in the core is different from that in the panel. The nozzle that prints the continuous fiber reinforcement material into the core is a third nozzle in the 3D printer. Alternatively, the continuous fiber reinforcement material in the core is the same as that in the panel. When printing the continuous fiber reinforcement material in the core, the panel printing material printed by the second nozzle is reused and printed into the core. Or, the continuous fiber reinforcement material in the core is different from that in the panel. The reused second nozzle prints the panel printing material when printing the panel, and switches to print a different continuous fiber reinforcement material into the core when printing the core. The process of adding continuous fiber reinforcement material during the printing of the sandwich core includes: During the printing process of at least a portion of the core by the first nozzle, the first nozzle is paused so that the continuous fiber reinforcement material can be printed into the at least a portion of the core by the second or third nozzle. The printing paths of the continuous fiber reinforcement material printed in at least some layers of the sandwich are multiple parallel paths; or, multiple intersecting paths. During the printing process of the first nozzle in the 3D printer, the printing temperature of the first nozzle is adjusted in a preset manner according to the printing parameters. When the 3D printer prints and stacks layers according to the printing parameters, it keeps the height of one of the first and second nozzles fixed, and switches the printing nozzle when the height of the other nozzle is higher or lower than the height of the fixed nozzle.

2. The method according to claim 1, characterized in that, The panel printing material includes continuous fiber reinforced material.

3. The method according to claim 2, characterized in that, The continuous fiber reinforced material includes at least one of continuous carbon fiber reinforced material, continuous glass fiber reinforced material, and continuous aramid fiber reinforced material; and / or, The continuous fiber reinforced material is a pre-impregnated continuous fiber reinforced material.

4. The method according to claim 2, characterized in that, The panel printing material and the sandwich core both contain the same continuous fiber reinforced material; The process of adding continuous fiber reinforcement material during the printing of the sandwich core includes: During the printing process of at least a portion of the core by the first printhead, the first printhead is paused so that the panel printing material can be printed onto the at least a portion of the core by the second printhead.

5. The method according to claim 4, characterized in that, The second nozzle prints in at least some layers of the core in an interlaced linear pattern.

6. The method according to claim 4, characterized in that, During the printing process of at least some layers of the core by the first printhead, for each of the at least some layers of the core, after switching to the second printhead, the panel printing material is printed onto the layer in one go through the second printhead.

7. The method according to claim 6, characterized in that, The method further includes: removing the panel printing material printed outside the sandwich from at least a portion of the layers of the sandwich.

8. The method according to claim 1, characterized in that, The panel printing material also includes at least one of polylactic acid filament, thermoplastic polyurethane elastomer filament, polyethylene terephthalate-1,4-cyclohexanediol filament, polyamide filament, and polycarbonate filament. The core material includes one of polylactic acid and thermoplastic polyurethane elastomer; and / or, The foaming material includes foamed microspheres.

9. The method according to claim 1, characterized in that, The printing parameters of the 3D printer include at least one of the following: the height of each printed layer, the width of the filament, the thickness of the outer wall of the model's side, the filling method inside the model, the filling density inside the model, the printing temperature, the printing platform temperature, the material flow rate, the filament retraction speed, the filament retraction distance, the printing speed, the fan speed, the support type, and the attachment type of the model on the printing platform.

10. The method according to claim 1, characterized in that, The process of determining the printing parameters of the 3D printer includes: Obtain the printing path of the panel, which is designed based on the geometric dimensions of the panel; The printing path of the core is obtained by importing the three-dimensional model of the core into 3D slicing software for slicing processing. The three-dimensional model is designed according to the geometric dimensions of the core.

11. A one-piece additively manufactured foam sandwich structure, characterized in that, The foam sandwich structure is manufactured using any one of the methods described in claims 1 to 10.

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