Crashworthiness of a Modular Assembled Multi-Cell CFRP Structure: Experimental and Numerical Investigation

Lightweight thin-walled energy-absorbing structures play a critical role in passive safety systems for automotive and aerospace engineering applications, yet simultaneously achieving high specific energy absorption and stable crushing behavior remains a persistent challenge. Inspired by the topology of natural honeycombs, this study proposes a novel modular assembled multi-cell carbon fiber reinforced polymer (CFRP) structure (MAMCS), fabricated via a cost-effective modular assembly strategy based on a wrapping process. Quasi-static axial crushing experiments combined with validated finite element simulations were employed to systematically investigate the effects of inner layup configurations ([0°/90°], [30°/−60°], [45°/−45°]), cell number, and inner sub-cell size on crushing behavior. Among the investigated layup configurations, the [0°/90°] inner layup exhibited superior mean crushing force (MCF) and specific energy absorption (SEA). Multi-cell architectures significantly enhanced load-bearing capacity and crushing stability through mechanical interactions among internal sub-cells. Parametric analyses further revealed that enlarging the inner sub-cell size elevates both MCF and SEA, although at the expense of a higher peak crushing force (PCF). A TOPSIS-based multi-criteria decision-making framework was applied to identify a preferred configuration that achieves a favorable balance between peak load mitigation and energy absorption efficiency. The proposed MAMCS, characterized by its simple modular assembly, cost-effective fabrication, and superior crashworthiness performance, offers a promising bio-inspired design strategy for developing high-performance lightweight energy-absorbing structures in axial impact applications.