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When designing structures that rely on sandwich panels, one of the most critical decisions is selecting the right thickness. They are built from two rigid skins bonded to a lightweight intermediary core, providing high strength and stiffness while keeping weight low. Their benefits are especially valuable in aerospace, automotive, and building industries. However, simply making the panel thicker does not always improve performance. Optimization requires understanding how thickness affects load bearing, buckling resistance, and overall efficiency.

Bending forces are predominantly resisted by the face layers. Increasing their thickness improves resistance to bending and reduces deflection under load. The core is not merely a spacer—it contributes significantly to structural behavior. Greater core thickness widens the moment arm between the skins, which significantly boosts the panel’s moment of inertia. This means even a small increase in core thickness can lead to a large gain in stiffness without adding much weight. However, if the core is too thick, it may become susceptible to shear failure or wrinkling, especially if the core material is not strong enough to support the increased spacing.

A balanced skin-to-core ratio is essential for optimal performance. If the face sheets are too thin relative to the core, the panel can experience delamination under load. Conversely, if the face sheets are too thick and the core too thin, the panel may become unnecessarily heavy without significant gains in strength. Thickness ratios must align with the anticipated stress profile, whether it is point loads.

Material choice also influences the ideal thickness. For example, a foam core may require a greater dimension to prevent compression failure, while a nomex honeycomb can maintain strength with less thickness due to its geometric efficiency. Long-term environmental exposure alters mechanical properties, so thickness must be chosen to account for durability over time, کانکس ساندویچ پانل not just initial strength.

Engineering software and finite element analysis can help simulate different thickness combinations to predict performance under complex stress environments. Physical trials are critical for confirming analytical predictions. In practice, the most efficient sandwich panels are those where thickness is strategically optimized—not simply increased—to deliver the required strength with minimal material use. This approach reduces cost, lowers transportation and installation expenses, and improves sustainability.

True optimization balances performance, weight, and cost in equal measure. It is not about the thickest panel, but the smartest one.