Crashworthiness optimization of biodegradable 3D-printed structures via geometric triggers and fuzzy Logic integration

This study investigates the crashworthiness of 3D-printed Polylactic Acid (PLA+) thin-walled tubes with engineered geometric cut-outs under quasi-static axial compression. Using a Taguchi L18 orthogonal array, the effects of wall thickness (2, 4, and 6 mm) and cut-out parameters (shape, dimension, count, and rows) were evaluated across key energy absorption metrics. Findings show that geometric triggers consistently lower initial peak force (Fᵢₚ), mitigating deceleration loads. Crucially, specific circular cut-out configurations in 4 mm and 6 mm specimens created a performance inversion, simultaneously enhancing Specific Energy Absorption (SEA) and improving Crush Force Efficiency (CFE) by over 12%. Circular cut-outs stabilized progressive folding as macroscopic crack arrestors, whereas angular cut-outs induced brittle failure under larger spacing. Fuzzy Logic and ANOVA confirmed wall thickness as the primary statistical driver, establishing robust guidelines for additively manufactured UAV safety components.