A Numerical Study on Crashworthiness in 3D Lattice Structures: Employing Shape Transformers

Periodic lattice materials exhibit tunable mechanical properties, yet the impact of non-cylindrical, non-circular strut cross-sections on crashworthiness remains largely unexplored. This study extends the concept of shape transformers—dimensionless ratios representing the area and second moment of area of a strut cross-section relative to its enclosing envelope—to two canonical lattice topologies: the octet and rhombic dodecahedron topologies (stretching-dominated and bending-dominated, respectively). Eleven distinct cross-sectional shapes (solid and hollow circular, diamond, and square) were systematically varied under constant area and constant envelope conditions to isolate microscale geometric effects on macroscopic impact response. Results demonstrate that adjusting Ψi alone can enhance specific energy absorption by up to 62% in bending-dominated lattices (compared to 18% in stretching-dominated lattices). Furthermore, the influence of geometric efficiency (λ = Ψi/Ψa) on plateau stress and energy absorption trends across topologies has been quantified. These findings establish shape transformers as significant design parameters for crashworthy lattice materials, and design charts are presented to facilitate the development of additive-manufactured cellular structures aimed at optimized energy absorption performance.