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<p>This study investigates the crashworthiness performance and deformation behavior of 3D-printed square polylactic acid (PLA) non-prismatic structures with cutouts. The analysis focuses on four key design parameters: the half conical angle (0<sup>o</sup>, 5<sup>o</sup>, 10<sup>o</sup>, and 15°), the diameter of the cutout (4, 8, 12, and 16&#xa0;mm), the number of cutouts (1, 2, 3, and 4), and the location of the cutouts (20, 30, 40, and 50&#xa0;mm). The printed structures were subjected to quasi-static axial compression loading to assess their crashing performance. Throughout the testing, both the crash load and energy absorption responses were meticulously recorded as a function of displacement. In addition to these measurements, the failure modes of the structures were thoroughly analyzed to identify the mechanisms driving deformation and fracture. The crashworthiness of the structures was evaluated using several key performance indicators, including the initial peak crash load<InlineEquation ID="IEq1"> <EquationSource Format="TEX">\(\:\:\left({\text{F}}_{\text{i}\text{p}}\right)\)</EquationSource> </InlineEquation>, total absorbed energy (U), mean crash load (<InlineEquation ID="IEq2"> <EquationSource Format="TEX">\(\:{\text{F}}_{\text{m}}\)</EquationSource> </InlineEquation>), specific energy absorption (SEA), and crashing force efficiency (CFE). To determine the optimal combination of design parameters, the complex proportional assessment (COPRAS) method was employed. The findings revealed that the A15/D8/N2/L30 configuration, characterized by a half conical angle of 15°, a cutout diameter of 8&#xa0;mm, two strategically placed cutouts, and a cutout location positioned 30&#xa0;mm from the upper edge of the tube, exhibited the highest overall crashworthiness performance among the tested designs.</p> Graphical abstract <p></p>

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Optimizing the design of perforated non-prismatic square 3D-printed structures for enhanced crashworthiness performance

  • 期刊论文

  • 发表日期：

    2026年2月2日

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  • Mahmoud M. Awd Allah,
  • Mahmoud F. Abd El-Halim,
  • Marwa A. Abd El-baky

摘要

This study investigates the crashworthiness performance and deformation behavior of 3D-printed square polylactic acid (PLA) non-prismatic structures with cutouts. The analysis focuses on four key design parameters: the half conical angle (0o, 5o, 10o, and 15°), the diameter of the cutout (4, 8, 12, and 16 mm), the number of cutouts (1, 2, 3, and 4), and the location of the cutouts (20, 30, 40, and 50 mm). The printed structures were subjected to quasi-static axial compression loading to assess their crashing performance. Throughout the testing, both the crash load and energy absorption responses were meticulously recorded as a function of displacement. In addition to these measurements, the failure modes of the structures were thoroughly analyzed to identify the mechanisms driving deformation and fracture. The crashworthiness of the structures was evaluated using several key performance indicators, including the initial peak crash load \(\:\:\left({\text{F}}_{\text{i}\text{p}}\right)\) , total absorbed energy (U), mean crash load ( \(\:{\text{F}}_{\text{m}}\) ), specific energy absorption (SEA), and crashing force efficiency (CFE). To determine the optimal combination of design parameters, the complex proportional assessment (COPRAS) method was employed. The findings revealed that the A15/D8/N2/L30 configuration, characterized by a half conical angle of 15°, a cutout diameter of 8 mm, two strategically placed cutouts, and a cutout location positioned 30 mm from the upper edge of the tube, exhibited the highest overall crashworthiness performance among the tested designs.

Graphical abstract