Thin-Walled Tubes (TWT) are widely used as crashworthiness elements to absorb and dissipate kinetic energy during collision through plastic deformation. Various design strategies, including nested tubes, triggers, and filling with lattices, are commonly used to enhance the crashworthiness of TWT. Additive Manufacturing (AM) offers unique opportunities to produce complex lattice-filled TWT with higher precision, but challenges persist in the design and fabrication of bi-tubular TWT to enhance crashworthiness. The aim of this study is to propose an approach for hybrid lattice filling in bi-tubular structures. In the preliminary phase, the parametric study was conducted to understand the influence of tube cross-section geometry, thickness, and trigger hole diameter on the crashworthiness of empty TWT using Taguchi’s L9 orthogonal array. Empty TWTs were fabricated using Selective Laser Sintering (SLS) with PA12 material and compressed uni-axially at 8 mm/min speed. In the second phase, bi-tubular TWT was filled with three different unit cells such as Cube, Kelvin, and Octet Truss (OT) having 30% relative density. In the lattice filling approach, two different strategies were followed such as uniform and hybrid lattice filling. Designed TWTs were fabricated and tested under uni-axial compression at two different speeds such as 8 mm/min and 8 mm/sec. Based on the results of the preliminary study, it has been observed that cross-section geometry and tube thickness significantly enhance SEA through an increase in the stiffness and number of folding. With the help of the Signal to Noise (S/N) ratio graph, appropriate levels were selected as input for the hybrid lattice-filling approach. The results of the second phase revealed that hybrid lattice filling significantly enhances the deformation modes, energy absorption, and crashworthiness properties of TWTs. Hybrid lattice-filled TWT offers better Specific Energy Absorption (SEA) as 18.32 kJ/kg at 8 mm/sec compression speed, which is 113.9% higher than empty and 42.8% higher than uniform lattice-filled TWT. This work demonstrated that adopting the hybrid lattice-filling approach is one of the potential ways to enhance the crashworthiness of protective equipment such as crash boxes and frames.
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