Crashworthiness performance of thin-walled structures towards design configuration in vehicle crash boxes application: a review

Lightweight structures with high energy absorption are crucial in engineering applications. Numerous studies have demonstrated that advanced thin-walled structures can collapse in a relatively controlled manner, exhibit a uniform force-displacement response, and achieve superior energy absorption efficiency compared to traditional structures. This work reviews the latest advancements in thin-walled structures for energy absorption, notably in vehicle crash boxes. Design configurations’ implications on crashworthiness are considered. Design configurations’ implications on crashworthiness are considered. Multi-cell tubes, corrugated tubes, bio-inspired structures, filled structures, and other modified structures are examples of such advanced energy absorption devices with specific advantages. Bio-inspired thin-walled structures could achieve more efficient and effective energy absorption, while corrugated structures can reduce the peak crushing force. Challenges in design and fabrication, along with potential developments, are discussed. This review contributes insights and ideas to the researchers and engineers in developing structures for energy absorption, particularly in vehicle crash box applications.