Crashworthiness Analysis of Variable‐ Orientation Carbon Fiber Composite Origami Tubes Fabricated via Vacuum‐Assisted Resin Transfer Molding ( VARTM )

ABSTRACT Thin‐walled structures have been widely used in engineering due to their exceptional energy absorption (EA) capabilities. The origami tube (OT), with its unique geometric features and folding advantages, exhibits excellent EA performance in the energy‐absorbing devices of vehicles. This paper presents a design for a detachable mold. It employs the vacuum‐assisted resin transfer molding (VARTM) process and utilizes T70012K unidirectional carbon fiber fabric to form the OT structure. It further investigates the deformation mechanisms and fiber bundle variations of the OT under axial loading conditions with different stacking configurations. The experimental results indicate that the [90°] ₂ /[0°] ₂ stacking configuration, combined with the advantages of the OT, exhibits optimal performance, achieving specific energy absorption (SEA) of 6.7 J/g. Compared to traditional metal square tubes, this design achieves an 81% weight reduction, a 54% increase in EA, and an 80% decrease in peak crushing force (PCF). This study provides valuable insights and guidance for the design of lightweight thin‐walled structures and efficient EA devices.