Development of a highly efficient, combined AM-forming process for the production of lightweight, energy-absorbing sandwich sheets.

The aim of this project is to develop energy-absorbing metallic sandwich sheets in which tailored additively manufactured core structures and cold-rolled face sheets are simultaneously joined and formed into the target geometry. The core structures will be topologically optimized and functionally graded to meet mechanical requirements, enabling ballistic energy to be absorbed through controlled plastic deformation while significantly reducing weight compared to steel plates. A purely mechanical, form-fit joining-forming process will be developed to achieve joint strength comparable to welded joints while maintaining high formability and reducing process time and manufacturing costs by combining joining and forming in a single step. A parametric design method will define an application-oriented process window linking core geometry, topology, formability and penetration resistance, from which suitable design and process parameters can be derived.