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Increasing transportation safety can be observed as one of the biggest engineering challenges. This challenge often needs to be combined with the need to deliver engineering solutions that are able to lower the environmental impact of transportation, by reducing fuel consumption. Consequentially, these topics have attracted considerable research efforts. The present work aims to address the previously cited challenges by maximizing the energy absorption capabilities of hybrid aluminum/composite shock absorbers with minimal thickness and mass. This engineering solution makes it possible to lighten vehicles and reduce fuel consumption, without compromising safety, in terms of crashworthiness capabilities. A numerical sensitivity study is presented, where the absorbed energy/mass (AE/m) and the absorbed energy/total panel thickness (AE/Htot) ratios, as a consequence of low-velocity impact simulations performed on six different shock absorbers, are compared. These hybrid shock absorbers have been numerically designed by modifying the core thickness of two basic absorbers’ configurations, characterized, respectively, by a metallic lattice core, intended to be produced through additive manufacturing, and a standard metallic honeycomb core. This work provides interesting information for the development of shock absorbers, which should be further developed with an experimental approach. Indeed, it demonstrates that, by integrating composite skins with a very light core producible, by means of additive manufacturing capabilities, it is possible to design shock absorbers with excellent performance, even for very thin configurations with 6 mm thickness, and to provide a significant increase in AE/m ratios when compared to the respective equal volume standard honeycomb core configurations. This difference between the AE/m ratios of configurations with different core designs increases with the growth in volume. In detail, for configurations with a total thickness of 6 mm, the AE/m increases in additive manufacturing configurations by approximately 93%; for those with a total thickness of 10 mm, the increase is 175%, and, finally, for those with a total thickness of 14 mm, the increase is 220%.

On the Effects of Core Microstructure on Energy Absorbing Capabilities of Sandwich Panels Intended for Additive Manufacturing