2026/01/07 by Alireza Baratian Sani Devin, A. Devin, Ali Keshavarzi +1
Engineering · #Cellular and Composite Structures #Structural Response to Dynamic Loads #Mechanical Behavior of Composites
paper · doi:10.1016/j.matdes.2026.115461
The pursuit of lightweight and crashworthy structures in transportation is often limited by the unpredictable and brittle failure of composites. This study introduces a novel bio-inspired hybrid structure, the Adhesively bonded Hybrid Euplectella -Inspired Structure (AHEIS), that overcomes this limitation by harnessing a “guided crushing” mechanism. Inspired by the Euplectella aspergillum sponge, the design uses an adhesively bonded aluminum framework to guide the progressive crushing of corner-reinforced Carbon Fiber Reinforced Polymer (CFRP) laminates, ensuring stable and predictable energy absorption. Crashworthiness was investigated experimentally and numerically under quasistatic oblique loading angles (10°–30°). A validated finite element model, with less than 10% deviation from experiments, captured complex damage, including delamination, petalling, and matrix cracking. Parametric studies showed that the [90/0] layup maintained exceptional crushing stability up to 25°, resisting global buckling. Optimized CFRP reinforcement increased specific energy absorption (SEA) by 79% and reduced load fluctuations by 93% compared to conventional aluminum tubes. Additionally, AHEIS outperformed six alternative bio-inspired geometries in both energy absorption and crushing stability. This guided crushing strategy establishes a new design paradigm for developing reliable, damage-tolerant, and lightweight energy absorbers for next-generation automotive applications.