Cushioning performance design of meta-sandwich structures inspired by Kirigami

Novel ultralight meta-sandwich structures inspired by Kirigami (MSS) are proposed in this study. The topological designs of uniform (MSS-U) and non-uniform (MSS-N) sizes are studied based on the inconsistent distribution of the biomaterials. First, MSS-U and MSS-N are manufactured using laser powder bed fusion (LPBF) technology, and energy absorption prediction formulas are successfully derived by extracting the experimental deformation features. It is found that MSS-N exhibits a higher energy absorption level than MSS-U. Compared to the conventional corrugated sandwich structures (CSS), the MSS achieves better crashworthiness indicators and more folding numbers. Moreover, the parameter effect of the MSS is analysed, and the minimum/maximum thickness and folding angle significantly influence the crashworthiness responses. The mechanical properties of MSS-N can be regulated by changing the folding angle while maintaining the same thickness. The MSS proposed in this study can achieve a higher energy absorption efficiency at the same density compared to other existing mechanical structures. Interestingly, the feasibility of applying MSS to automobiles and plant protection drones is verified by changing the materials and macro-configurations. The design concept presented in this study provides a promising method for obtaining sandwich structures with excellent cushioning properties for engineering protective equipment.