Optimization of bi-hexagonal crash box design using metal 3D printing technology for enhanced crashworthiness

This research is important for improving crashworthiness performance in vehicles by optimizing the crash box design using Selective Laser Melting (SLM) metal 3D printing technology. Although conventional crash boxes are effective, a more efficient and lightweight design is required for better energy absorption during impact. The methods used in this study include numerical simulation with ANSYS and experimental testing to validate the results. The research findings indicate that the optimized crash box model achieves the highest Energy Absorption (EA) value of 24.834 kJ and Specific Energy Absorption (SEA) of 142.25 kJ/kg, which are higher than those of other models. Deformation pattern findings show that the optimized model results in more controlled and symmetric deformation, thanks to increased wall thickness and optimized geometry. This reduces the stress at the structural corners, allowing for progressive and stable deformation, and minimizes the risk of sudden structural failure. This study makes a significant contribution to the development of more efficient and safer crash box designs for vehicle applications. • Optimization of bi-hexagonal crash box design improves energy absorption. • Selective Laser Melting (SLM) enhances crashworthiness with 3D printing. • The optimized crash box achieved the highest Energy Absorption (24.83 kJ). • Simulation and experimental tests confirmed improved deformation stability. • Wall thickness and structure length were key factors for energy absorption. • The optimized model showed a 42% increase in Specific Energy Absorption (SEA).