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The material property and geometric ratios between three key elements of a toucan (Ramphastos toco) beak were determined, in order to examine how this natural structure achieves its strong, lightweight form. The beak structure was reduced to three distinct layers: an outer, keratin base shell; connected foam reinforcement; and a central hollow core. Seven factors, key material properties and geometries, were selected to analyse the simulated performance. Taguchi’s method of orthogonal arrays was utilised to determine the significance of main and two-way interactions between these factors with eight simulations. The analysis of the results gives direction to application of these ratios for increased composite beam performance through design. Previously published work proving the dependency between shell and foam materials was used to validate the analysis, when the same conclusion was drawn in this study. Three significant conclusions emerged: a deformation reduction of 50% averaged over the array with a hollow compared to a solid core was observed; deviation from the bioinspired Young’s modulus and compressive strength ratios resulted in significant lower performances; and finally, the geometric ratios are significant and worthy of further research – thickening the materials from the initial condition in fact reduced the simulated beam’s performance, contrary to the logical assumption.

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