Effect of 3D-Printed Honeycomb Core on Compressive Property of Hybrid Energy Absorbers: Experimental Testing and Optimization Analysis

This paper presents an innovative method of constructing energy absorbers, whose primary function is to effectively transform kinetic energy into strain energy in events with high deformation rates. Hybrid specimens are proposed considering thin-walled windowed metallic tubes filled with 3D-printed hexagonal honeycombs made of PET-G and ABS thermoplastic. The patterned windows dimensions vary from 20 x 20, 20 x 30, 15 x 20 and 15 x 30 mm2. Although using polymers in engineering and thin-walled sections is not new, their combination has not been explored in this type of structure designed to withstand impacts. Specimens resist out-of-plane quasi-static axial loading, and test results are analyzed, demonstrating that polymer core gives the samples better performance parameters than unfilled samples regarding energy absorption (Ea), load rate (LR), and structural effectiveness (eta). An optimization procedure using specialized software was applied to evaluate experimental results, which led to identifying the optimal window geometry (16.4 x 20 mm2, in case) and polymer to be used (ABS). The optimized sample was constructed and tested for axial compression to validate the optimization outcomes. The results reveal that the optimal sample performed similarly to the estimated parameters, making this geometry the best choice under the test conditions.