An innovative cellular structure, the Menger Fractal Cube (MFC), is introduced and studied systematically for the first time for low-velocity energy absorption applications. Formed through a recursive process of removing smaller cubes from a larger one, the MFC exhibits a hierarchically repeating pattern of cubical voids, resulting in a lightweight and highly complex structure. MFCs of three orders were fabricated using Selective Laser Melting (SLM) with highly ductile AlSi7Mg material. These structures were subjected to dynamic compression tests at impact velocities of 5.7 ms−1, 8 ms−1 and 10 ms−1 corresponding to input energies of 100 J, 200 J and 300 J respectively, both experimentally and numerically. Results reveal a unique failure mode involving buckling, shearing, shear band localisation and tensile yielding, resulting in a smooth force response in the plateau region. In contrast to conventional cellular structures, MFC structures exhibit multi-stage yield platforms without force drops. Notably, higher-order MFCs demonstrate extensively improved load bearing, crashworthiness, and energy-absorbing properties under dynamic loading conditions. This study provides crucial insights for optimising Additive Manufacturing (AM) cellular structures for dynamic energy absorption scenarios, with implications for automotive, sports, aerospace, and defence applications.
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