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Optimal Design and Additive Manufacturing of Polymeric Metamaterials for Energy Absorption and Impact Mitigation

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Abstract:

Architected metamaterials fabricated by additive manufacturing offer deterministic geometries and tunable mechanical properties that can outperform conventional foams in energy absorption and impact mitigation. In this work, origami honeycomb and plate-lattice metamaterial concepts are unified within a common, quantitatively characterised metamaterial. An optimization-based design approach is employed to maximise absorbed energy while keeping the peak stress below a predefined threshold, using metamaterial geometric parameters as design variables. The objective function is evaluated through post-processing of Abaqus compression simulations on automatically generated designs. Owing to the high computational cost, the optimisation is performed using an evolutionary algorithm with a limited number of evaluations, yielding a best-performing design rather than a global optimum. Despite this limitation, the results elucidate the critical roles of buckling in limiting initial peak stress and of contact in enhancing post-peak energy absorption, and they highlight the significant potential for further performance gains through expanded design space exploration.

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Info:

Periodical:

Key Engineering Materials (Volume 1047)

Pages:

213-221

Online since:

April 2026

Authors:

Victor Daniel Fachinotti*, Erik Andreassen, Sylvain Gouttebroze

Keywords:

Energy Absorption, FFF, Impact Mitigation, Metamaterial, Optimal Design, TPU

Export:

RIS, BibTeX

Permissions:

Creative Commons CC BY 4.0

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* - Corresponding Author

References

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