Two novel hybrid materials for use in sandwich cores of structural materials are designed, manufactured and mechanically tested. Each material is a hybrid of metal and polymer foam. One set of hybrids is fabricated using an aluminium micro-truss filled with varying densities of polyurethane foam. Increases up to 120% in stiffness, 372% in strength, 740% in resilience and 106% in impact energy over the aluminium micro-truss are obtained from compression and impact testing. Furthermore, the stiffness of these hybrids can be tailored according to the density of the polyurethane foam. Another set of hybrids is fabricated using a rapid prototyped ABS polymer truss that is foamed and electroplated with nanocrystalline nickel. Increases up to 1525% in stiffness, 1165% in strength and 650% in energy absorption over the foamed ABS truss are obtained. Furthermore, the gain in strength, stiffness and energy absorption outweigh the gain in density in these hybrid materials.

Two novel hybrid materials for use in sandwich cores of structural materials are designed, manufactured and mechanically tested. Each material is a hybrid of metal and polymer foam. One set of hybrids is fabricated using an aluminium micro-truss filled with varying densities of polyurethane foam. Increases up to 120% in stiffness, 372% in strength, 740% in resilience and 106% in impact energy over the aluminium micro-truss are obtained from compression and impact testing. Furthermore, the stiffness of these hybrids can be tailored according to the density of the polyurethane foam. Another set of hybrids is fabricated using a rapid prototyped ABS polymer truss that is foamed and electroplated with nanocrystalline nickel. Increases up to 1525% in stiffness, 1165% in strength and 650% in energy absorption over the foamed ABS truss are obtained. Furthermore, the gain in strength, stiffness and energy absorption outweigh the gain in density in these hybrid materials.