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Application of additively manufactured shape-optimized core fillers in composite aircraft landing gear structures
 
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1
Rzeszów University of Technology, Powstańców Warszawy 12,35-35-959 Rzeszów, Poland
 
2
Warsaw University of Technology, Pl. Politechniki 1, 00-661 Warsaw, Poland
 
These authors had equal contribution to this work
 
 
Corresponding author
Maciej Kalwara   

Rzeszów University of Technology, Powstańców Warszawy 12,35-35-959 Rzeszów, Poland
 
 
 
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ABSTRACT
This paper presents the application of additively manufactured (3D-printed) shape-optimized core fillers in composite sandwich structures, demonstrated on a full-scale aircraft landing gear component. The study compares conventional foam cores with 3D-printed honeycomb structures and evaluates their performance through three-point bending tests. Furthermore, the integration of complex-shaped fillers into a composite landing gear structure is described. The results highlight the advantages of additive manufacturing in terms of geometric accuracy, functional integration, and manufacturability. The solution has been implemented in a production aircraft, confirming its practical applicability.
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