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<p>Hybrid tubes with lattice-based cores exhibit superior crashworthiness compared with their individual components, while additively manufactured cellular lattices enable more controllable deformation modes than conventional structures. However, re‑entrant honeycomb auxetic structures (REHAS) have not yet been effectively integrated into cylindrical hybrid tubes. Conventional approaches typically employ extruded Cartesian-based auxetic cores, which lead to non-uniform interaction with the cylindrical shell and limited structural efficiency. To address this limitation, this study proposes a novel family of three-dimensional REHAS cores designed directly in cylindrical (polar) coordinates, derived from a conventional two‑dimensional Cartesian auxetic model. The proposed designs—including blade, rotary, and their modified variants—enable continuous geometric adaptation along the circumferential direction, resulting in improved core–shell interaction and structural integrity compared with conventional extruded 3D cores. Quasi-static axial compression tests were conducted on fused filament fabrication (FFF)-manufactured hybrid tubes made of carbon‑fiber‑reinforced polyamide. The results demonstrate substantial improvements in crashworthiness relative to empty tubes. Energy absorption increased from 5.6 J to 30.2 J (≈539%), while specific energy absorption improved from 3.7 J g<sup>-1</sup> to 6.6 J g<sup>-1</sup>. Meanwhile, the collapse force reduced by up to 50%, and crushing force efficiency reached 71.2%. Among the investigated configurations, rotary cores exhibited the highest energy absorption, whereas blade cores were more effective in reducing the collapse force. The modified blade cores provided the best balance between weight and energy absorption, leading to the highest specific energy absorption. Parametric investigations further show that increasing wall thickness, cell density, and the number of core–shell connections enhances energy absorption and improves the overall crushing response of the hybrid tubes.</p> Graphical Abstract <p></p>

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Crashworthiness Enhancement of Additively Manufactured Cylindrical Tubes Using Polar-Adapted Auxetic Honeycomb Cores: Experimental Study under Quasi‑Static Axial Loading

  • 期刊论文

  • 发表日期：

    2026年7月7日

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  • Mohammad Kamali,
  • Mahmoud Kadkhodaei,
  • Mohsen Badrossamay

摘要

Hybrid tubes with lattice-based cores exhibit superior crashworthiness compared with their individual components, while additively manufactured cellular lattices enable more controllable deformation modes than conventional structures. However, re‑entrant honeycomb auxetic structures (REHAS) have not yet been effectively integrated into cylindrical hybrid tubes. Conventional approaches typically employ extruded Cartesian-based auxetic cores, which lead to non-uniform interaction with the cylindrical shell and limited structural efficiency. To address this limitation, this study proposes a novel family of three-dimensional REHAS cores designed directly in cylindrical (polar) coordinates, derived from a conventional two‑dimensional Cartesian auxetic model. The proposed designs—including blade, rotary, and their modified variants—enable continuous geometric adaptation along the circumferential direction, resulting in improved core–shell interaction and structural integrity compared with conventional extruded 3D cores. Quasi-static axial compression tests were conducted on fused filament fabrication (FFF)-manufactured hybrid tubes made of carbon‑fiber‑reinforced polyamide. The results demonstrate substantial improvements in crashworthiness relative to empty tubes. Energy absorption increased from 5.6 J to 30.2 J (≈539%), while specific energy absorption improved from 3.7 J g-1 to 6.6 J g-1. Meanwhile, the collapse force reduced by up to 50%, and crushing force efficiency reached 71.2%. Among the investigated configurations, rotary cores exhibited the highest energy absorption, whereas blade cores were more effective in reducing the collapse force. The modified blade cores provided the best balance between weight and energy absorption, leading to the highest specific energy absorption. Parametric investigations further show that increasing wall thickness, cell density, and the number of core–shell connections enhances energy absorption and improves the overall crushing response of the hybrid tubes.

Graphical Abstract