Crash performance of a novel bio-inspired energy absorber produced by additive manufacturing using PLA and ABS materials

Abstract Thin-walled structures are one of the important safety components used in vehicles. They are placed in the front parts of the vehicles to minimize the impacts that occur in the event of a collision, and they absorb the impact force by changing shape in the event of a collision. Crash boxes have high-impact absorption, low weight, and low-cost expectations. In the design of crash boxes, thin-walled structures are preferred due to their high deformation capability. In this study, the additive manufacturing method was used to produce thin-walled structures. Thin-walled structures were produced by additive manufacturing methods using PLA and ABS materials. The manufactured crash boxes were tested using an impact test. In the experimental results, the energy absorption ability of the crash boxes produced from PLA and ABS materials was examined, and high fragility was observed. The experimental results were verified by finite element analysis of the crash boxes made using PLA and ABS materials.