Toucans use a sandwiched technique to create a lightweight, impact-resistant composite with a high tensile outer layer and low density rigid but cushiony inner layer.
Toucans have bills a third of their body length but only a twentieth of their body mass. These massive beaks can take a beating. They are impact-resistant due to their layered composite structure featuring hexagonal scales over a stiff but flexible foam surrounding a central hollow core. Bills stronger than concrete are tough enough for sparring but light enough to fly easily.
Longer suggestion (based on the Awe, inspire, act texts):
Toucans have bills a third of their body length but only a twentieth of their body mass. These massive beaks are a lightweight yet strong structure used to maintain the bill's structure during aggressive fights or food seeking without adding much mass to ease the demands of flight. They are impact-resistant due to their layered composite structure featuring hexagonal scales over a stiff but flexible foam surrounding a central hollow core, propagating forces away from the point of impact. This strategy can inspire architects, engineers and designers to develop lightweight but impact-resistant structures and materials stronger than the concrete.
