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Reusable 3D-Printed Thermoplastic Polyurethane Honeycombs for Mechanical Energy Absorption
Alin Bustihan1, Razvan Hirian1, Ioan Botiz1,2
1Department of Physics of Condensed Matter and Advanced Technologies, Faculty of Physics, Babeș-Bolyai University, 400084 Cluj-Napoca, Romania.
Polymers
|November 27, 2025
Summary
Reusable 3D-printed thermoplastic polyurethane (TPU) honeycomb structures show excellent energy absorption. The hexagonal TPU 95A design achieved 47% energy absorption efficiency, offering a cost-effective solution for impact protection.
Area of Science:
- Materials Science
- Mechanical Engineering
- Additive Manufacturing
Background:
- Honeycomb structures are known for their energy absorption capabilities.
- 3D printing offers customization for complex geometries.
- Thermoplastic polyurethanes (TPUs) are versatile elastomers with tunable properties.
Purpose of the Study:
- To evaluate the mechanical energy absorption of reusable 3D-printed honeycomb structures.
- To investigate the influence of TPU variants and honeycomb geometry on performance.
- To identify optimal configurations for energy absorption applications.
Main Methods:
- Fused Deposition Modeling (FDM) was used to fabricate honeycomb structures from TPU 70A, 85A, and 95A.
- Mechanical properties of TPU filaments were analyzed at varying printing temperatures.
- Out-of-plane compression testing was performed on hexagonal and circular honeycomb configurations (with and without 30° twist).
Main Results:
- The hexagonal honeycomb from TPU 95A achieved the highest energy absorption efficiency (47%).
- This performance surpassed expanded polystyrene and neared advanced lattice structures.
- Twisted configurations improved crushing load efficiency (up to 73.5%), enhancing stress distribution and reusability.
- TPU 95A offered the best balance of elasticity, integrity, and reusability.
Conclusions:
- 3D-printed TPU honeycomb structures are a viable, cost-effective alternative for energy absorption.
- These structures show potential for impact protection systems, automotive safety, and sports equipment.
- Material selection (TPU 95A) and geometric design (hexagonal, twisted) are critical for optimizing performance.
