Crashworthiness performance of 3D printed thermoplastic polymer composite hexagonal multi-cellular tubes: A biomimetic approach for enhanced energy absorption

The biomimetic approach has gained significance in designing the lightweight structures due to its ability to enhance mean crushing force and specific energy absorption capacity. This technique increases energy absorption and decreases initial peak load, making it an effective method for structural performance optimization. The current work presents innovative biomimetic hexagonal multi-cellular tube structures to enhance energy absorption performance. The proposed structures were created through the fused deposition modelling (FDM)-based 3D printing technique which has the capability for precise control over the design as well as the material properties. Experimental testing was conducted to evaluate the crashworthiness of hexagonal multi-cellular tubes subjected to quasi-static axial loads with varying masses and configurations. In order to decide the most efficient energy-absorbing structure, the Technique for Order of Preference by Similarity to Ideal Solution (TOPSIS) was employed. The findings showed that the PE-HM6 structure exhibited superior crashworthiness characteristics and was the best choice for energy absorption. The current study provides a detailed outline for designing high-performance energy absorbers with the help of biomimetic principles and multi-cellular structures for improved energy absorption.