Evaluation of crush and energy absorption characteristics of corrugated origami tube by additive manufacturing

Abstract Origami tube (OT) has attracted significant attention in the realm of thin‐walled structures owing to their remarkable energy‐absorption capabilities. Nevertheless, their deformation modes, particularly buckling, present considerable stability challenges. In this research, we introduce a novel corrugated structure to enhance the energy absorption and stabilize the deformation mode of OT. The corrugated origami tube (COT) was manufactured using high‐specific modulus, high‐strength, and lightweight short carbon fiber‐reinforced nylon via 3D printing, followed by axial quasi‐static compression tests. The findings demonstrate that the incorporation of corrugations in COT greatly stabilizes tube deformation, boosting energy absorption by 21.3% compared to OT and reducing the peak crashworthiness force by up to 21.37%. Finite element analysis accurately replicates the experimental performance of the COT, affirming the feasibility of the simulation. Optimization using the Non‐dominated Sorting Genetic Algorithm II (NSGA‐II) produced a Pareto front, revealing trade‐offs among various crashworthiness indicators and offering a flexible design approach to meet diverse requirements. This study provides valuable insights and guidance for the design of lightweight, thin‐walled structures. Highlights The corrugated structure effectively stabilizes deformation mode of the OT. COT significantly improves energy absorption and reduces initial peak force compared to OT. The approach of multi‐objective optimization provides a variety of solutions for different needs.