Multi-objective optimization design of a circular core paper sandwich panel

Abstract Ensuring sufficient mechanical performance while enabling lightweight design is critical for utilizing paper sandwich panels in the furniture industry. To design lightweight sandwich panels that balance mechanical properties and cost, this study developed a circular core paper sandwich panel (CCPSP) and investigated its structural efficiency using multi-objective optimization. The response surface method (RSM) based on Box–Behnken design was utilized to establish mathematical models relating the paper tube spacing, inner diameter, and height to the out-of-plane compressive strength, density, and cost. The resulting models effectively revealed the coupled effects of the parameters on the responses. Subsequently, the models were optimized using the non-dominated sorting genetic algorithm II (NSGA-II) to find the Pareto optimal trade-offs between maximizing compressive strength while minimizing its density and cost. The optimization solution resulted in an optimal set of paper tube geometries that maximized the structural efficiency of CCPSP. Overall, lower tube height conferred superior structural efficiency, while tube spacing and diameter were constrained. The results highlight the potential of CCPSP as an efficient and sustainable material for furniture manufacturing, enabled by multi-objective optimization of its structure.