The Role of Cross-Sectional Design and Orientation in Governing Energy Absorption of Additively Manufactured...

This study investigates the influence of strut cross-sectional geometry and orientation on the crashworthiness of octet truss lattice structures produced via Multi Jet Fusion (MJF) using Polyamide 12 (PA12) material. All lattice configurations were designed and printed at a constant relative density of approximately 30%, ensuring equal mass and material usage across geometries. Quasi-static compression tests were conducted on lattices featuring circular, elliptical, rectangular, and square struts, with the latter two also evaluated at 0° and 90° orientations relative to the loading direction. Energy absorption (EA), specific energy absorption (SEA), crush force efficiency (CFE), and mean plateau stress metrics were employed to evaluate the structural energy absorption efficiency. The results highlight that strut geometry and orientation significantly alter mechanical behavior due to differences in moments of inertia. The circular strut lattice, used as the reference configuration, achieved an SEA of 0.79 J/g. Among the tested designs, the elliptical lattice exhibited the most pronounced variation: the non-rotated version showed the lowest SEA (0.63 J/g, ~20% lower than the reference), whereas the 90° rotated version yielded the highest SEA (0.92 J/g, ~16% higher). Rectangular struts displayed a similar trend, with rotated specimens outperforming their non-rotated counterparts. Square struts, however, showed negligible differences between orientations, as their rotational inertia remained constant. Overall, the findings demonstrate that optimizing strut cross-sections can enhance crashworthiness by improving energy dissipation and stabilizing deformation mechanisms under compressive loading. The rotated elliptical cross-section emerged as the most efficient configuration, offering superior SEA and crush stress efficiency. The findings highlight that cross-sectional design and orientation provide an effective mechanism for tuning mechanical performance in lightweight lattice materials without altering overall density or topology. These insights emphasize the potential of geometric tailoring in lattice design to meet safety and lightweight requirements in transportation, defense and biomedical applications.