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<p>This study presents a novel 3D-printed shell auxetic metamaterial with filleted re-entrant unit cells, designed for high-performance automotive bumpers. The proposed design combines tunable unit-cell fillet radius and width, enabling exceptional auxetic behavior, enhanced stiffness, high load-bearing capacity, and superior energy absorption. Mechanical performance was evaluated through experimental compression tests and finite element simulations. Results indicate that increasing the unit-cell fillet radius significantly enhances maximum force, stiffness, and specific energy absorption (SEA) by 17–23%. Additionally, increasing unit-cell width produces up to a fourfold rise in peak force, substantial improvements in stiffness, and increases SEA from 191.5 to 236.6&#xa0;mJ/g. Stress and strain analyses demonstrate that deformation concentrates in central and load-aligned regions, while the highly negative Poisson’s ratio confirms exceptional auxetic performance. The tunability of the mechanical response through geometric parameters enables precise control over stiffness, peak load, and energy absorption. These features suggest that implementing this metamaterial in automotive bumpers can improve crash energy dissipation, reduce forces transmitted to occupants, and lower structural weight. The novelty of this work lies in the integration of filleted and tunable-width unit cells to simultaneously optimize auxetic response and mechanical performance, offering a versatile platform for next-generation impact-resistant vehicle components.</p>

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A novel 3D-printed shell auxetic structure with filleted unit cells for high-performance automotive bumpers

  • 期刊论文

  • 发表日期：

    2026年3月17日

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  • Lei Li,
  • Qiang Zhou,
  • Chengzuan Zhang,
  • Jinwei Zhang

摘要

This study presents a novel 3D-printed shell auxetic metamaterial with filleted re-entrant unit cells, designed for high-performance automotive bumpers. The proposed design combines tunable unit-cell fillet radius and width, enabling exceptional auxetic behavior, enhanced stiffness, high load-bearing capacity, and superior energy absorption. Mechanical performance was evaluated through experimental compression tests and finite element simulations. Results indicate that increasing the unit-cell fillet radius significantly enhances maximum force, stiffness, and specific energy absorption (SEA) by 17–23%. Additionally, increasing unit-cell width produces up to a fourfold rise in peak force, substantial improvements in stiffness, and increases SEA from 191.5 to 236.6 mJ/g. Stress and strain analyses demonstrate that deformation concentrates in central and load-aligned regions, while the highly negative Poisson’s ratio confirms exceptional auxetic performance. The tunability of the mechanical response through geometric parameters enables precise control over stiffness, peak load, and energy absorption. These features suggest that implementing this metamaterial in automotive bumpers can improve crash energy dissipation, reduce forces transmitted to occupants, and lower structural weight. The novelty of this work lies in the integration of filleted and tunable-width unit cells to simultaneously optimize auxetic response and mechanical performance, offering a versatile platform for next-generation impact-resistant vehicle components.