Composite Plastic Hybrid for Automotive Front Bumper Beam

The bumper beam is a crucial component of the automobile bumper system, responsible for absorbing impact energy and enhancing the safety of passengers during collisions. This paper presents the design and experimental analysis of a 3D-printed composite-plastic hybrid light structure, designed as a collapsible energy absorber. Exploratory testing was conducted using low-impact tests to investigate the failure mechanism and energy absorption capacity of a spiral structure. The design process involved optimizing the spiral diameter by testing specimens with varying diameters between 0.5 cm and 2.5 cm, while keeping other geometric parameters constant. The study employed three types of 3D composite structures, including printed thermoplastic, printed thermoplastic reinforced with Kevlar fiber composite, and printed thermoplastic filled with foam. The thermoplastic-foam composite with nine spirals (diameter = 0.97 cm) yielded the best results. The new design demonstrated high energy absorption capacity and a controlled and progressive failure mechanism, making it a suitable candidate for energy absorption applications.