Parametric Optimization of 3D Printed Reentrant Metamaterials for Energy Absorption in Load‐Bearing Automotive Applications

ABSTRACT Metamaterials are engineered materials with tailored structures that exhibit extraordinary mechanical properties not found in conventional materials. These structures have emerged as transformative solutions in many devices due to their lightweight nature, enhanced energy absorption, and tunable mechanical response. In particular, auxetic metamaterials with negative Poisson's ratios, such as reentrant honeycombs, have shown great promise in automotive applications. Lightweight load‐bearing components are essential in automotive applications to enhance performance, reduce weight, and improve durability. This study presents a parametric cylindrical metamaterial structure designed for lightweight load‐bearing components by redesigning 2D reentrant cells into cylindrical geometries and utilizing 3D‐printing technology. It became possible to fabricate complex lattices with tunable cell parameters that significantly influence mechanical properties such as equivalent stiffness, strain distribution, and energy absorption capacity. Experimental validation through force‐displacement testing of 3D‐printed samples confirmed the accuracy of numerical models. Subsequently, the validated model was used to optimize cell parameters for increased energy absorption. The results demonstrated that the new cylindrical metamaterial can be optimized via its cell parameters to meet specific requirements. Ultimately, cylindrical reentrant metamaterials are placed as steering column tubes to tailor quasi‐static crush stiffness and energy absorption, maintaining low weight and geometric compatibility with existing steering systems.