Due to its low material costs and versatility in producing diverse products, 3D printing technology has attracted attention from researchers studying the crashworthiness of automotive energyabsorbing structures. This paper conducts quasistatic experimental research on automotive energyabsorbing structures, such as crash beams and honeycomb fillers, made from different base materials but with identical structural dimensions, using 3D printing technology. A comparative analysis of their mechanical responses and deformation modes is performed. Furthermore, finite element simulations are employed to study the influence of structural parameters on crashworthiness indicators. The results show that the loaddisplacement curves of 3Dprinted PLA crash beams and honeycomb filler structures exhibit similar trends to those of metal structures and reflect the deformation characteristics of automotive energyabsorbing structures. Increasing the wall thickness raises the relative density, which enhances the crashworthiness of both the crash beam and the honeycomb structure. Additionally, changes in the cell size also affect the crashworthiness of the honeycomb structure. This paper proposes an optimization scheme for automotive energyabsorbing structures based on 3D printing technology, systematically studying the effects of structural parameters on crashworthiness through experiments and simulations. This research offers valuable insights for designing educational tools in automotive engineering and analyzing automotive energyabsorbing structures.

3D printing  /  bumper beam  /  honeycomb  /  three-point bending  /  axial compression