Joining thin sandwich materials with a total thickness of up to approximately 1.5 mm is a major technological and structural challenge because the joint must ensure reliable load transfer without causing unacceptable damage to the face sheets and core. Based on a literature review, this paper analyses the main joining approaches applied to this class of materials, namely adhesive bonding, mechanical joining, hybrid joints, and selected thermal and thermomechanical methods. These approaches are assessed in terms of technological feasibility, joint strength, and the risk of local damage. The results indicate that adhesive bonding is the most broadly applicable approach because it enables load transfer without perforation and without pronounced local deformation. Mechanical joining methods are suitable only selectively, as they increase the risk of delamination, local indentation, and stress concentration. Hybrid joints appear to be a promising solution in terms of reliability and resistance to peel loading, whereas thermal and specialized methods are particularly suitable for thermoplastic and metal-polymer systems. The selection of a joining technology should therefore be based not only on joint strength but also on the extent of disturbance to the original multilayer structure.
thin sandwich materials, joining, adhesive bonding, mechanical joining.
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