Advances in composite crashworthiness: material properties, failure mechanisms, and design strategies

Abstract This comprehensive overview examines the crashworthiness and structural performance of composite materials, integrating decades of research to emphasize improvements in material attributes, failure processes, and design techniques. The research assesses hybridization and modern manufacturing methods, highlighting their impact on SEA, CFE, and structural integrity. Significant breakthroughs, including nanotechnology and natural fiber composites are examined, focusing on environmental sustainability and mechanical performance. The discussion encompasses real-world applications in the automotive, aerospace, and defense sectors, highlighting the exceptional energy absorption and lightweight properties of composite materials. The review highlights significant deficiencies in scalability, cost-efficiency, and multi-scale modeling, promoting bio-inspired designs, hybrid systems, and enhanced recycling techniques to comply with advancing safety and environmental regulations.