To enhance the residual energy‐absorption (EA) of low-velocity impact-damaged CFRP square tubes, this study investigates the influence of stacking angles on the damaged tubes' residual EA. Through simulation and theoretical analysis, a well-designed stacking angles is proposed to optimize the residual EA. Initially, a simplified method of low-velocity impact damage of composite materials is proposed, by which a discontinuous damage mechanics finite element model is established and experimentally verified. Subsequently, various layup sequences are examined, and their impact on energy absorption is evaluated using several performance indices, including initial peak load, average load, energy absorption, specific energy absorption, and crushing load efficiency. The findings demonstrate that the designed stacking angles significantly enhances the residual energy absorption of low-velocity impact-damaged square tubes. Moreover, the study verifies the efficacy of the stacking angles design by investigating actual damage conditions, encompassing factors such as damage size, location, and stress concentration.
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