Crashworthiness evaluation of 3D-printed hybrid-design multi-cell energy absorbers under lateral compression for unmanned aerial vehicles


Atahan M. G., Zeybek H., Ozturk S.

Journal of the Brazilian Society of Mechanical Sciences and Engineering, vol.48, no.1, 2026 (SCI-Expanded) identifier

  • Publication Type: Article / Article
  • Volume: 48 Issue: 1
  • Publication Date: 2026
  • Doi Number: 10.1007/s40430-025-06043-5
  • Journal Name: Journal of the Brazilian Society of Mechanical Sciences and Engineering
  • Journal Indexes: Science Citation Index Expanded (SCI-EXPANDED), Scopus, Aerospace Database, Communication Abstracts, Compendex, INSPEC, Metadex, Civil Engineering Abstracts
  • Keywords: Additive manufacturing, Crash box, Crashworthiness performance, Energy absorber, Thin-walled structure
  • Abdullah Gül University Affiliated: Yes

Abstract

Energy absorbers can be strategically integrated into critical areas of unmanned aerial vehicles to protect their structural integrity and electronic components in the event of an accident. In this study, hybrid-design multi-cell energy absorber configurations were proposed, and their crashworthiness performance and collapse mechanisms were comparatively analyzed. Hybrid energy absorbers were designed considering circular, square, hexagonal, and re-entrant unit cell geometries. The energy absorber configurations were produced via additive manufacturing. Compared to the single-cell circular energy absorber, the hybrid-design multi-cell approach resulted in a higher peak crushing force value, while offering considerable enhancements in other crashworthiness parameters. Configuration 3 is recommended for use in energy absorber applications in unmanned aerial vehicles due to its superior crashworthiness performance. Moreover, in hybrid-design multi-cell energy absorbers, the selection of layer geometries significantly influences deformation capability. Compared to the single-cell circular configuration (Configuration 1), Configuration 3 demonstrated superior crashworthiness performance by increasing the MCF, EA, and SEA values by 7.47, 4.47, and 1.41 times, respectively.