A filling lattice with actively controlled size/shape for energy absorption

This study unveils a groundbreaking development: the chain lattice structure (CLS), a unique lattice with the capability to actively adjust its size and shape for filling diverse thin-walled structures, thereby enhancing their energy absorption characteristics. Traditional lattice structures, known for excellent energy absorption, are constrained by fixed sizes and shapes post-fabrication, limiting their adaptability to various energy-absorbing structures. The CLS introduces a revolutionary lattice structure dynamically modifying dimensions and shape. Employing selective laser sintering (SLS), we craft CLS prototypes using nylon 11 material, followed by rigorous quasi-static compression experiments. The congruence between experimental and simulation analyses validates our model's accuracy. CLS actively adjusts within varying cross-sectional thin-walled square tubes, demonstrating substantial improvements in energy absorption and compression stability compared to empty tubes (ETs). Additionally, CLS adapts to diverse cross-sectional shapes, including circular, hexagonal, and triangular tubes. Comparative assessments reveal significant enhancements in energy absorption and compression stability for CLS-filled tubes. Moreover, the pre-deformed CLS model was filled with different shapes of front rails, and its axial crashworthiness and deformation pattern stability were significantly improved compared with the unfilled front rails. In summary, CLS's flexibility in adjusting to thin-walled structures of varying dimensions and shapes holds immense promise for enhancing their performance across a wide range of applications.