Design of a Lightweight Origami Composite Crash Box: Experimental and Numerical Study on the Absorbed Energy in Frontal Impacts

Origami-shaped composite structures are currently being explored for their ability to absorb energy in a progressive and controlled manner. In vehicle passive safety applications, this prevents the occurrence of peak forces that could potentially cause injuries to vehicle passengers. The work presents the design of a carbon fiber-reinforced polymer (CFRP) crash box for a Formula Student race car, using a numerical model validated by experimental tests. An initial characterization of the material is conducted according to the standards. Following, six origami samples are manufactured and subjected to crash tests to gather accurate experimental data. The numerical model is validated on the tests and used for the design of the race car’s impact attenuator. The designed crash box meets the Formula Student requirements while reducing the total mass by 14% and the maximum deceleration of 21% compared with the previous design. The study confirms the potential use of origami structures to improve crashworthiness while reducing vehicle weight.