A review of origami thin-walled structures for energy absorption: geometric design, theoretical modelling, and manufacturing

Origami-inspired thin-walled structures are increasingly used in crashworthiness design because pre-folded geometries can guide collapse, reduce peak crushing force, and improve energy absorption. This review summarizes recent progress in origami-inspired thin-walled structures for energy absorption, focusing on geometric design, collapse behaviour, theoretical modelling, and manufacturing. Major structural routes are discussed, including full-patterned origami tubes, origami-ending and trigger-based tubes, multi-cell, graded and layered structures, and origami-inspired mechanical metamaterials, with attention to their collapse-control mechanisms, crashworthiness advantages, and limitations. Theoretical and semi-theoretical models are examined in terms of assumptions, applicability, and predictive limits. Manufacturing routes for metallic, polymeric, and composite origami structures are also reviewed, highlighting their effects on geometric fidelity and engineering feasibility. Finally, key challenges and future directions for practical origami crashworthy structures are identified.