Crashworthiness optimization of biodegradable 3D-printed structures via geometric triggers and fuzzy Logic integration

Abstract

This study investigates the crashworthiness of 3D-printed Polylactic Acid (PLA+) thin-walled tubes with engineered geometric cut-outs under quasi-static axial compression. Using a Taguchi L18 orthogonal array, the effects of wall thickness (2, 4, and 6 mm) and cut-out parameters (shape, dimension, count, and rows) were evaluated across key energy absorption metrics. Findings show that geometric triggers consistently lower initial peak force ($F_{ip}$), mitigating deceleration loads. Crucially, specific circular cut-out configurations in 4 mm and 6 mm specimens created a performance inversion, simultaneously enhancing Specific Energy Absorption (SEA) and improving Crush Force Efficiency (CFE) by over 12%. Circular cut-outs stabilized progressive folding as macroscopic crack arrestors, whereas angular cut-outs induced brittle failure under larger spacing. Fuzzy Logic and ANOVA confirmed wall thickness as the primary statistical driver, establishing robust guidelines for additively manufactured UAV safety components.