Optimization of energy absorption in bio-inspired cylindrical lattice structures: an experimental investigation with Box–Behnken design

Purpose Energy-absorbing structures play a crucial role in various engineering applications, including automotive, aerospace and protective equipment. This study aims to enhance the energy absorption (EA) efficiency of bio-inspired cylindrical lattice structures by optimizing their geometric parameters. Design/methodology/approach Cylindrical bio-inspired lattice structures were fabricated using masked stereolithography 3D printing equipment with Acrylonitrile Butadiene Styrene-like resin. Box–Behnken design was used to investigate the geometrical parameters cell radius (6.350, 15.875 and 25.400 mm), arc count (2, 3 and 4) and cell thickness (2.0, 2.5 and 3.0) for the energy absorption capacity of these structures under compression loading. Findings The first peak load (FPL), absorbed energy and specific absorbed energy of the bio-inspired cylindrical lattice structures increased continuously with increasing cell thickness and arc count and decreasing cell radius. The highest results were 2,620.69 N, 40.16 J and 14.75 J/g for FPL, absorbed energy and specific absorbed energy, respectively. Optimum results were obtained by increasing cell thickness and arc count and decreasing cell radius. Originality/value This research contributes to the field of bio-inspired lattice structures 3D printing by systematically optimizing key geometric parameters for EA applications. The integration of the Box–Behnken methodology with bio-inspired designs provides a novel approach to develop lightweight and high-performance structures for potential applications.