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Origami crash tubes have concerned nowadays due to their superior crashworthiness behaviour by controlling the initial buckling force and collapse modes. In this paper, a new multi-layered origami pattern is proposed and fabricated, and a numerical study is performed under quasi-static axial compressive loading and validated by the experimental result of the fabricated origami crash box. To compare the energy absorption efficiency of this proposed origami tube, its mechanical responses are normalised with the conventional octagonal tube. Moreover, the crashworthiness behaviour of 64 samples is investigated for the dihedral angle 2 θ , outer layer height  e , and module number  M  in the parametric study. It is demonstrated that by increasing  M  for tubes with a constant value of  e , the critical angle of  θ  decreases. By increasing the value of  e  for tubes; while, considering the values of  M  and  θ  constant, the mechanical responses of the tubes increase, and these trends are valid as long as  θ  is below the critical angle. The number of modules  M , angle  θ , and outer layer height  e  have the highest effect on the mechanical responses. Finally, the results show that by maintaining the specific energy absorption of the conventional octagonal tube, the initial peak force can be reduced about 55%. In consequence, the proposed pattern reduces the initial peak force while maintaining the specific energy absorption.

Energy absorption investigation of octagonal multi-layered origami thin-walled tubes under quasi-static axial loading