Energy Absorption Mechanisms Research Articles

Impact of lattice designs and production parameters on mechanical properties of AlSi10Mg in laser powder bed fusion

Abstract This study investigates the impact of lattice designs and production parameters on the mechanical properties of AlSi10Mg fabricated using Laser Powder Bed Fusion (L-PBF). The research explores the production and performance of gyroid, diamond, and lidinoid lattice structures under varying scanning speeds (600, 900, 1,200 mm s−1). Key findings indicate that scanning speed significantly influences mechanical properties and energy absorption capabilities. The gyroid lattice structure produced at 600 mm s−1 exhibited the highest compressive strength (76.51 MPa) and energy absorption (28.57 MJ m−3). SEM-EDS analysis revealed no substantial structural defects, while porosity and microstructural deformations were observed at higher scanning speeds. Finite element simulations demonstrated localized buckling and fissure formation in lattice structures under compressive loads. The study highlights the critical role of production parameters in optimizing the mechanical performance of L-PBF-manufactured AlSi10Mg, offering insights into achieving cost and time efficiencies in additive manufacturing processes. This comprehensive analysis contributes to advancing the application of L-PBF in producing complex, high-performance aluminum alloy components for industrial use.

Recent Advances in Additive Manufacturing of Fibre-Reinforced Materials: A Comprehensive Review

Additive manufacturing (AM) plays a significant role in the 4th Industrial Revolution due to its flexibility, allowing AM equipment to be connected, monitored, and controlled in real time. In advance, the minimum waste of material, the agility of manufacturing complex geometries, and the ability to use recycled materials can provide an advantage to this manufacturing method. On the other hand, the poor strength and durability of the thermoplastics used in the manufacturing process are the major drawback that keeps AM behind common production methods such as casting and machining. Fibre-reinforced polymers can enhance mechanical properties, advance AM from the commonly used polymers, and make AM competitive against conventional production methods. The main focus of the current review is to examine the work conducted in the field of reinforced additively manufactured technologies in the literature of recent years. More specifically, this review discusses the conducted research in the composite fibre coextrusion (CFC) additive manufacturing techniques developed over the past years and the materials that can be used. In addition, this study includes an up-to-date comprehensive review of the evaluation of fibre-reinforced 3D printing along with its benefits in terms of mechanical response, namely tensile, flexural, compression and energy absorption, anisotropy, and dynamic properties. Finally, this review highlights possible research gaps regarding fibre-reinforced AM and proposes future directions, such as deeper investigations into energy absorption and anisotropy, to position fibre-reinforced AM as a preferred fabrication method for ready-to-use parts in cutting-edge industries, including automotive, aerospace, and biomedical sectors.

Optimizing mechanical properties and pioneering biodegradable polymer blends for superior energy-absorbing structures used in sport helmets

Replacing elements made of conventional plastics (like polystyrene) with biodegradable substitutes is part of the trend of sustainable development and waste reduction. The manuscript covers issues related to the design, manufacturing and testing of sports helmet protective inserts made of biodegradable material. The FEM numerical simulations carried out by the authors allowed to determine the optimal desirable mechanical properties (Re = 8.5–65 MPa, E = 500–8000 MPa for 30 × 30 mm inserts; Re = 10.5–60 MPa, E = 500–7500 MPa for 48 × 48 mm inserts; Re = 13–95 MPa, E = 400–8500 MPa for 55 × 55 mm inserts) and geometric parameters (wall thickness equal to 0.2–0.5 mm, height of 20 mm), ensuring the formation of a plastic fold, which is the most effective energy-absorbing mechanism. The conducted quasi-static compression, bending and dynamic tensile strength tests allowed to determine blends with appropriate proportions of durable PLA with more plastic PBAT, PBS and TPS that meet the established criteria: PLA50PBAT50, PLA30PBAT70 and PLA30TPS70.

Crashworthiness and stiffness improvement of a variable cross-section hollow BCC lattice reinforced with metal strips

The ultra-lightweight structures with high mechanical properties and energy absorption behaviors are focused on the innovation structural design. The design strategy of implementing novel unit cells within architecture materials such as lattice materials enables the attainment of unparalleled combinations of mechanical properties and functionalities while minimizing weight. The most common method to design light-weight lattice materials is optimizing the geometric configurations of the unit cells. However, changing the geometric boundary of lattice structures can also be a good solution to improve the mechanical characteristics and energy absorption behaviors of the lattice materials. In this work, a novel variable cross-section hollow (VCH) lattice was established to improve the energy absorption capacity. By adding metal strips on the edge of the VCH lattices, a new reinforced variable cross-section hollow (RVCH) lattice with metal strips was developed to further enhance the stiffness and energy absorption capacity. The stainless VCH and RVCH lattices were additively manufactured by Selective Laser Melting (SLM) using an EP-M450H metal 3D printer. The quasi-static compressive characteristics and energy absorption behaviors of RVCH lattices were studied experimentally. Finite element modeling was implemented to study the energy absorption mechanism of RVCH lattices. A parametric analysis based on the finite element models was conducted to study the influence of different metal strips on the energy absorption capacity of RVCH lattices. The results show that the RVCH lattices with metal strips attaching to the vertical edges can signally enhance energy absorption of lattice structures with good load uniformity. Furthermore, the natural frequencies analysis indicate that the higher bending stiffness and the tensile stiffness can be achieved for RVCH lattices. This novel lattice is more stable as a load-bearing structure and more efficient as an energy absorber, which can provide guidance in designing innovative lattice structures with excellent mechanical properties and energy absorption capacity.

Experimental and Simulation Study of Fiber-Reinforced and Foam-Filled Anti-Tetrachiral and Re-Entrant Structures

Negative Poisson's ratio (NPR) honeycomb structures exhibit excellent properties, including resistance to compression, impact resistance, and energy absorption. To better study NPR structures, this paper investigates two different methods to enhance the mechanical properties and energy absorption capabilities of re-entrant and anti-tetrachiral structures. Fiber reinforcement and polyurethane foam filling methods were used to address material enhancement issues, aiming to achieve structures with high specific energy absorption. Specimens were fabricated using selective laser sintering technology with three different material configurations, including nylon, carbon fiber-reinforced nylon, and glass fiber-reinforced nylon, for comparative analysis. Additionally, some specimens were filled with polyurethane foam. Quasi-static compression tests indicated that both glass fiber-reinforced nylon and foam filling significantly improved the material's stiffness, initial peak stress, and energy absorption, although the "auxetic" effect was weakened. Subsequently, finite element methods were used to simulate the deformation modes and mechanical properties of the two NPR structures, and the numerical results showed good agreement with the experimental results.

Effect of fractal dimension on mechanical behaviour and energy absorption of Menger sponge-inspired fractal structures

Effect of fractal dimension on mechanical behaviour and energy absorption of Menger sponge-inspired fractal structures

Enhancing Shear Strength in Hybrid Metal-Composite Single-Lap Joints Using Z-pins Fabricated via Fused Filament Fabrication

This paper investigates the interfacial shear strength of hybrid metal-composite single-lap joints (SLJs) reinforced with stainless steel Z-pins fabricated by fused filament fabrication (FFF). The joints were created by 3D printing an orthogonal array of 2 mm diameter steel Z-pins onto a steel substrate using FFF. The Z-pins were then embedded into a basalt fibre (BF)-fabric/epoxy resin composite using the Ultrasonically Assisted Z-FibreTM (UAZ) method to form a high-strength and tough interface. The results demonstrate that steel Z-pins produced via FFF effectively enhance the shear strength of the hybrid metal-composite SLJs, significantly improving joint performance. The study also explores the influence of Z-pin volume fraction and embedding height on SLJ shear strength. It was found that higher volume fractions and greater embedding heights of the Z-pins contribute to the increased shear strength. Compared to unreinforced joints, the maximum shear strength of the steel Z-pin reinforced joints increased by 120.1%. This enhancement is attributed to the effective energy absorption mechanisms, primarily facilitated by the frictional pull-out, plastic deformation and shear fracture of Z-pins accompanied by the formation of ductile dimples. These mechanisms suppress crack propagation and improve joint integrity. This study presents an innovative approach for fabricating hybrid metal-composite joints with enhanced toughness and strength.

Experimental investigation on tailoring compressive properties and energy absorption of 3D printed gradient star re-entrant hybrid auxetic structure

Purpose Fused filament fabrication (FFF) is a widely used 3D printing technique for the fabrication of mechanical metamaterials with intricate geometries. Gradient strategy is applied to geometric parameters of gradient star re-entrant hybrid auxetic (GSRA) structure. Deformation behaviour is studied under compressive loading. The purpose of this study is to investigate the influence of gradient geometric parameters on mechanical properties, namely, specific strength (SS), specific modulus (SM) and specific energy absorption (SEA). Design/methodology/approach Response surface methodology (RSM) is implemented for the design of experiments of gradient geometric parameters to minimize the number of experimental tests. Acrylonitrile butadiene styrene material is used for the fabrication of GSRA structures by FFF technique. The best set of gradient parameters has been optimized maximizing all three responses using RSM and artificial neural network optimization technique. Findings During compressive testing, row-wise deformation is observed with two-stage plateau regions, which results in increase in SEA of the structure. Furthermore, based on analysis of variance and 3D response plots, it is found that height gradient is the most influencing gradient geometric parameter on SS and SM, whereas the wall thickness gradient has maximum influence on SEA. Meanwhile, the interaction effect of wall thickness gradient and height gradient has maximum influence on SS, SM and SEA. Research limitations/implications This study of applying gradient strategy to geometric parameters is limited to GSRA structure under compressive loading. In addition, findings are valid within the selected range of gradient geometric parameters. These findings are useful for the selection of gradient geometric parameters to maximize SS, SM and SEA of GSRA structure simultaneously. These outcomes pave the way for designing light-weight gradient hybrid auxetic structures in the field of construction, aerospace, automobile and biomedical engineering. Originality/value Limited experimental study is available on investigating the influence of gradient geometric parameters on mechanical properties, namely, SS, SM and SEA, and deformation behaviours of hybrid auxetic structures. This study directly addresses the above research gaps.

3D-printable Kresling-embedded honeycomb metamaterials with optimized energy absorption capability

Abstract Kresling origami structure has attracted significant interest for achieving extraordinary mechanical properties. In this study, we proposed a new strategy to develop 3D-printable Kresling-embedded honeycombs (KEHs) based mechanical metamaterials and achieve optimized mechanical energy absorption capability. By exploiting the twisted deformation modes and boundary constraints, various KEH reinforced metamaterials were designed, where their deformation behaviors and energy absorption properties were investigated using finite element analysis and quasi-static compression tests. Effects of orientation twisting angle, boundary constraint and crease tilting angle on the deformation behaviors of these KEH reinforced metamaterials were studied to optimize their energy absorption properties. Finally, deformation behaviors and energy absorption properties of KEH reinforced metamaterials incorporated of KEH arrays in both 2D structure and 3D structures were studied. Both experimental and simulation results showed that the proposed KEH reinforced metamaterials achieved much more stable compression behaviors and higher energy absorption capabilities than those of the traditional honeycomb structures. This study provides a novel KEH reinforcement strategy for 3D printed metamaterials with optimized energy absorption capabilities to dramatically expand their practical applications.

Mechanical, thermal, and microstructure analysis of 3D printed polyolefin elastomer-acrylonitrile butadiene styrene blends for tunable mechanical properties

Fused Deposition Modeling (FDM) has emerged as a cost-effective and user-friendly technique that has garnered significant attention in recent years. However, challenges persist when printing soft materials using FDM technology. This study proposes a solution by blending a soft polyolefin elastomer (POE) with a stiffer material, acrylonitrile butadiene styrene (ABS). A comprehensive experimental investigation utilizing a direct pellet printing method was conducted to 3D print POE-ABS blends in various ratios (10%, 30%, and 50% ABS content). The study encompassed material preparation, 3D printing, SEM (Scanning Electron Microscopy) analysis, Dynamic Mechanical Thermal Analysis (DMTA), uniaxial tensile testing, and compression testing to assess the mechanical properties and energy absorption capabilities of the 3D printed blends. The results of the DMTA showed that the blends with a higher amount of ABS have a larger area under the Tan δ curve, indicating their ability to absorb more energy. The SEM images revealed that as the proportion of ABS increases, the gaps between layers and beads become smaller. The mechanical properties of the pure printed POE, such as its elongation at break and tensile strength, were 2138% and 2.83 MPa, respectively. However, as the ABS content increased, the samples exhibited more rigid behavior, with a final transition to 50/50 ratio resulting in 9.4 MPa tensile strength and 160% elongation at break. The energy absorption test demonstrated that the sample with 30% ABS content has the highest energy absorption capability among all the tested samples. This research underscores the potential of blending soft and stiff materials to tailor properties for additive manufacturing applications, emphasizing the significance of material composition in achieving desired mechanical performance, printability, and functionality in printed objects.

Out-of-plane impact characteristics of missing rib-plate type anti-tri-chiral honeycomb

Chiral honeycomb structures, renowned for their superior mechanical properties, find extensive application in passive safety protection and beyond. However, existing research predominantly centers on chiral honeycomb structures, neglecting discussions on the energy absorption capabilities of anti-chiral honeycomb structures subjected to out-of-plane impacts. In view of this, an innovative design method is proposed in this paper to construct a series of anti-tri-chiral honeycomb structures (MATCH-θ) with missing rib-plate and excellent crashworthiness by skillfully designing and replacing the nodal elements of the anti-tri-chiral structures. Subsequently, the effects of the constitutive angle θ and the wall thickness t of the cellular elements were investigated using a validated finite element model, revealing the energy absorption mechanism of MATCH-θ. It is shown that this type of structure has better crashworthiness performance compared to the conventional anti-tri-chiral honeycomb structure ATCH-90°. In particular, the MATCH-110° structure with t = 0.1 mm showed a 36% increase in specific energy absorption, a 36% increase in mean crush force, and a 35% increase in crush force efficiency compared to the conventional anti-tri-chiral honeycomb structure ATCH-90° with the same mass. The completion of this study provides valuable insights into the design and optimization of future honeycomb structures for crashworthiness.

Compressive behavior of additively manufactured lightweight structures: Infill density optimization based on energy absorption diagrams

The use of 3D-printed components as load-bearing structures is widely studied, while their use as energy absorbers constitutes a gap in the additive manufacturing (AM) field. Most of the reported works address the compressive behavior of AM parts up to low strains (<15%), thus omitting many important properties. Therefore, this paper presents the compression characterization of Polylactic Acid (PLA) samples with different infill densities-IDs (10–100% range, with a step of 10%) fabricated by material extrusion (MEX) AM process. The physical (dimensional accuracy, printing time and sample mass) and mechanical (elastic, strength, strain and energy absorption) properties are determined and discussed in detail, along with the failure mechanisms that occur in the samples. Moreover, an ID optimization is performed based on the energy absorption diagrams (EAD), a unique approach in the AM field. The highest values of compressive strength (81 MPa) and modulus (1306.6 MPa) are found for 90%-ID, over 2.2% higher than those obtained for 100%-ID. On the other hand, based on three different approaches, EAD identified 30%-ID as optimal. The 30%-ID samples absorb the largest amount of energy (12 MJ/m3) at the lowest (ideal) peak stress value (23.57 MPa), which is 69.1% lower than that for 100%-ID. At low IDs (<30%), the samples exhibit a brittle behavior, changing to a ductile one with the increase of ID (≥40%). The MEX-printed PLA samples show a dimensional relative error below 0.15%, and the optimization process reduces the amount of filament material by 54.3% and the printing time by 42.7%.

Compressive Mechanical Properties and Energy Absorption of Cubic Spherical Hollow Cellular Material Based on the Rod and Curved Surface Structure

Cellular materials, such as lattices and honeycombs, were widely used for structural protection owing to their excellent mechanical properties. By combining the excellent characteristics of lattice and honeycomb curved surface structures, this study designed a cell called Cubic Spherical Hollow (CSH), which had the advantages of orthogonal isotropy and better spatial connectivity. Inspired by the micro-structural arrangement of bamboo fiber and conch shell, we designed the new CSH cellular materials through the interlayer offset strategy. Then, the effects of interlayer offset on the mechanical properties and compression deformation behavior were explored experimentally and simulatively. Compared with other cellular materials, CSH cellular materials exhibited excellent mechanical properties with higher specific strength and specific modulus. The arrangement offsets of the CSH cells between different layers led to a change in the deformation mechanism from a rod’s compressive mode to a combination of a rod’s compressive mode and curved surface’s bending mode. The initial peak stress and plateau stress decreased with the increased arrangement offsets of the CSH since the extruded protrusions of the structure filled the holes and reduced the lateral expansion behavior of the material in the pressurized environment. This phenomenon also reduced the transverse expansion and prevented the sudden change in stress in the constrained space, indicating that the structural deformation was stable and had excellent cushioning and energy absorption properties. In this study, the cellular material design strategy opens a new avenue for energy absorption.

Mechanical energy absorption capacity of the porous Ti-6Al-4V alloy under quasi-static and dynamic compression

Porous materials are very efficient in absorbing mechanical energy in different applications. In the present study, porous materials based on the Ti-6(wt.%)Al-4V alloy were manufactured with the use of two different powder metallurgy methods: i) blended elemental powder approach using titanium hydride (TiH2) as well as V-Al master alloy powders and ii) using hydrogenated Ti-6-4 pre-alloyed powder. The powder compacts were sintered with additions of ammonium bicarbonate as a pore-holding removable agent. The emission of hydrogen from hydrogenated powders on vacuum sintering and the resulting shrinkage of powder particles permitted the control of the sintering process and creation of anticipated porous structures. Mechanical characteristics were evaluated under quasi-static and dynamic compressive loading conditions. Dynamic compression tests were performed using the direct impact Hopkinson pressure bar technique. All investigations aimed at characterizing the mechanical energy-absorbing ability of the obtained porous structures. The anticipated strength, plasticity, and energy-absorbing characteristics of porous Ti-6-4 material were evaluated, and the possibilities of their application were also discussed. Based on the obtained results, it was found that porous Ti-6-4 material produced with a blended elemental powder approach showed more promising energy absorption properties in comparison with pre-alloyed powder.

Particularities on the Low-Velocity Impact Behavior of 3D-Printed Sandwich Panels with Re-Entrant and Honeycomb Core Topologies

This work describes, through experimental and numerical investigations, the mechanical behavior and energy absorption characteristics of 3D-printed sandwich panels with cellular cores subjected to low-velocity impact. Using fused deposition modeling techniques (FDM), three different sandwich panels, one with a regular hexagonal core and two with re-entrant cores at 0 and 90 degrees, were fabricated. The sandwich panels were subjected to low-velocity impact, at impact energies of 10 J and 15 J. A comprehensive investigation of the panels’ behavior through experimental testing and numerical simulation was conducted. The results indicate that the sandwich panel with a 90 degrees re-entrant core is stiffer and absorbs the largest amount of impact energy but, at the same time, suffers significant damage to the upper facesheet. The 0 degrees re-entrant core is compliant and provides both impact resistance and good energy absorption characteristics. Such a sandwich panel finds its application in the construction of personal protective equipment, where the aim is to minimize the forces transmitted during low-velocity impacts and maximize the total absorbed energy. Re-entrant core sandwich panels prove to be very good candidates for replacing the honeycomb core sandwich, depending on the desired engineering application.

Mechanical properties of lander bionic buffer structure based on additive manufacturing

In order to meet the energy absorption requirements of the landing buffer, this paper starts with the buffer filling material of the buffer, draws on the Kelvin structure and spiral structure, and applies the engineering bionics principle to design and establish two structural models: a soccerball-like bionic structure and a multi-spiral bionic structure. Considering the energy absorption and reusability requirements of the lander buffer structure, the bionic structure sample is prepared by additive manufacturing technology and NiTi alloy with shape memory effect. The mechanical properties, energy absorption and recoverability of the sample are analyzed and verified by simulation and experiment. The results show that the accuracy of the numerical simulation is verified by comparing the force-displacement curves of the simulation test and the isometric static pressure test; the multi-spiral bionic structure has better mechanical properties, and its maximum energy absorption is 3096.23 J; the recovery rates of the two structures are as high as 98.02%and respectively 97.12%, and the recovery rate of the soccerball-like bionic structure is slightly higher. This study uses additive manufacturing to prepare the leg-type lander buffer bionic structure, which provides a reference for the bionic design of the lander buffer structure.

Dynamic response of hemispherical-shell sandwich structures subjected to underwater impulsive loading

In this study, experiments and numerical simulations are designed on aluminum sandwich structures with a hemispherical-shell core layer under underwater impact loading to investigate the dynamic response and energy absorption mechanisms. After the hemispherical-shell sandwich panels are designed and fabricated, they are loaded using an experimental apparatus incorporating fluid–structure interactions. The dynamic response of the sandwich panels is captured using the three-dimensional digital image correlation (3D-DIC) method of high-speed photography, and the energy-absorption mechanisms are analyzed via numerical simulation. This study primarily considers the effects of installation orientation, shock wave impulse and adhesive film on the sandwich panels. The results indicate that the deformation mode and impact resistance of the sandwich panels vary depending on the installation orientation. The displacement at the midpoint of the dry facesheet is linearly related to the shock wave impulse. At non-dimensional impulses exceeding 0.0085, the impact resistance of the forward installation target plate is higher. Additionally, the adhesive film significantly affects the deformation mode of the hemispherical-shell core layer. Its removal slightly increases the proportion of energy absorbed at the core. Quantitative and qualitative analyses of the structure-response-energy relationship are performed on the hemispherical-shell sandwich panels, thus providing guidance for investigations pertaining to the underwater impact resistance of future metal sandwich structures.

High Mechanical Performance of Lattice Structures Fabricated by Additive Manufacturing

Lattice structures show advantages in mechanical properties and energy absorption efficiency owing to their lightweight, high strength and adjustable geometry. This article reviews lattice structure classification, design and applications, especially those based on additive manufacturing (AM) technology. This article first introduces the basic concepts and classification of lattice structures, including the classification based on topological shapes, such as strut, surface, shell, hollow-strut, and so on, and the classification based on the deformation mechanism. Then, the design methods of lattice structure are analyzed in detail, including the design based on basic unit, mathematical algorithm and gradient structure. Next, the effects of different lattice elements, relative density, material system, load direction and fabrication methods on the mechanical performance of AM-produced lattice structures are discussed. Finally, the advantages of lattice structures in energy absorption performance are summarized, aiming at providing theoretical guidance for further optimizing and expanding the engineering application potential of lattices.

Axial Impact Response of Carbon Fiber-Reinforced Polymer Structures in High-Speed Trains Based on Filament Winding Process.

The continuous increase in the operating speed of rail vehicles demands higher requirements for passive safety protection and lightweight design. This paper focuses on an energy-absorbing component (circular tubes) at the end of a train. Thin-walled carbon fiber-reinforced polymer (CFRP) tubes were prepared using the filament winding process. Through a combination of sled impact tests and finite element simulations, the effects of a chamfered trigger (Tube I) and embedded trigger (Tube II) on the impact response and crashworthiness of the structure were investigated. The results showed that both triggering methods led to the progressive end failure of the tubes. Tube I exhibited a mean crush force (MCF) of 891.89 kN and specific energy absorption (SEA) of 38.69 kJ/kg. In comparison, the MCF and SEA of Tube II decreased by 21.2% and 21.9%, respectively. The reason for this reduction is that the presence of the embedded trigger in Tube II restricts the expansion of the inner plies (plies 4 to 6), thereby affecting the overall energy absorption mechanism. Based on the validated finite element model, a modeling strategy study was conducted, including the failure parameters (DFAILT/DFAILC), the friction coefficient, and the interfacial strength. It was found that the prediction results are significantly influenced by modeling methods. Specifically, as the interfacial strength decreases, the tube wall is more prone to circumferential cracking or overall buckling under axial impact.

Fluid-structure interaction mechanism in shear thickening fluid/Foam composite for advanced protective structures

Fluid-structure interaction (FSI) between shear thickening fluid (STF) and soft materials is pivotal in designing advanced protective structures. This study delves into the FSI mechanisms within a composite structure known as STF/Foam, which features the infusion of STF into foam. Through comprehensive drop weight tests, the STF/Foam exhibited exceptional cushioning performance. In addition to analyzing FSI from the perspective of structural materials, this study also examines it from the STF standpoint, enabling a multi-faceted understanding of the energy absorption mechanism. To accurately characterize the rheological properties of STF, a novel decoupling method is proposed, accounting for both temporal and spatial inhomogeneities of STF. The research findings indicate that the viscosity variation of STF significantly enhances the energy absorption capabilities of the STF/Foam composite. This study reveals the intricate fluid-solid coupling mechanism between STF and foam. The STF demonstrates a unique combination of shear resistance akin to high-viscosity fluids and the easy flow characteristics of low-viscosity fluids. The modulation of STF viscosity optimizes the structural deformation pattern, thereby rationalizing the energy absorption mechanism of the composite. Consequently, STF/Foam showcases superior cushioning performance. Further investigation into various parameters associated with STF and foam highlights their influence on the structural cushioning performance. These insights lay a theoretical foundation and provide design guidelines for the future development of STF-based controllable protective structures.