Natural Fibre and Hybrid Composite Thin-Walled Structures for Automotive Crashworthiness: A Review

Natural fibres, valued for their low density, cost-effectiveness, high strength-to-weight ratio, and efficient energy absorption, are increasingly emerging as alternatives to synthetic materials in green composites. Although they cannot fully replace synthetic counterparts, like carbon, in structural applications due to their inferior mechanical performance, combining them through hybridization presents a potential solution. This approach promotes a balance between environmental benefits and mechanical efficiency. Recently, the transportation sector has shifted its focus towards delivering lightweight and crashworthy composite structures to improve vehicle performance, address safety concerns, and minimise environmental impact through the use of eco-friendly materials. The crashworthiness of energy absorbers, typically thin-walled structures, is influenced by several factors, including their material and geometric design. This paper presents a comprehensive overview of recent studies focused on the crashworthiness of fibre-reinforced, thin-walled composites under axial crushing. It explores different aspects, such as their materials, cross-sections, stacking sequences, triggering or filling mechanisms, and the effect of loading rate speed. Emphasis is placed on natural-fibre-based materials, including a comparative analysis of synthetic ones and their hybridization. The primary objective is to review the progress of solutions using green composites as energy absorbers in the automotive industry, considering their lightweight design, crashworthiness, and environmental sustainability.