In this study, inspired by the design of a step-folding cup, a similar structure, the novel folded cup energy absorption structure (FES), was proposed. This structure is fabricated using selective laser sintering (SLS) technology with nylon 11. Through rigorous simulation analysis, the energy absorption characteristics of the FES have been systematically elucidated. Subsequently, the deformation behavior and mechanical properties under axial compression were investigated using finite element analysis (FEA) and practical experimentation. FES achieves unique mechanical characteristics, including negative stiffness and a novel deformation mode. To validate the effectiveness of the proposed structure, a comparative analysis was conducted between experimental and simulation results. This paper analyzes the compressive mechanical properties of the FES from four perspectives: the diameter of each layer, the thickness of the inclined buffer layer, the number of layers, and the proportion of the inclined buffer layer at the end. The findings demonstrate that a decrease in diameter deviation, in essence, is positively correlated with both the dimensional ratio and the thickness of the inclined buffer layer, leading to significantly improved energy absorption capabilities in the FES model. Compared to the experimental benchmark model, the parametric model demonstrates up to 112.58% enhancement in specific energy absorption.
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