Crashworthiness Assessment and Multi-Criteria Ranking of 3D printed beetle elytra inspired multicellular structures using the TOPSIS Approach

The hierarchical design and naturally evolved load-bearing efficiency of structures inspired by the beetle elytra have made them desirable choices for crashworthiness applications. In this investigation, additively manufactured beetle elytra-inspired multicellular structures were designed and fabricated using the Fused Deposition Modelling (FDM) technique. Six different configurations of bionic designs were developed and evaluated through axial static crushing experiments to evaluate their energy absorption capability. The experimental investigation revealed that the unique internal configuration of the elytra-based design improved energy absorption and structural stability when subjected to crushing load. The Technique for Order Preference by Similarity to Ideal Solution (TOPSIS) technique was utilised to select the optimal design among the variants, incorporating key performance indicators including specific energy absorption, initial peak force, and mass. The ranking analysis determined that the PG-FC3 configuration is the most effective design. The predictive regression models showed high accuracy, with R² values exceeding 0.89 and MAPE under 12%, validating the model’s reliability for design assessment. This study illustrates the potential of structures inspired by beetle elytra in the development of lightweight and efficient crashworthy structures for automotive, aerospace, and defence applications.