Aluminium foam and TPMS-based tubular lattice structures (T-TLS) were of interest due to their superior energy absorption capabilities and inherent lightweight characteristics. However, their synergistic functionality in a composite form remained unexplored. In pursuit of augmenting the crashworthiness characteristics, aluminum foam was filled into T-TLS to form foam-filled T-TLS. FE models were established and validated using lateral crushing experiments. Foam-filled T-TLS exhibited higher energy absorption (EA) compared to the sum of empty T-TLS and foam filler, primarily attributed to the interaction between T-TLS and foam filler. Compared to single circular filled tubes (SCFT) with the same outer sizes and mass, foam-filled T-TLS revealed markedly enhanced crashworthiness, with EA and SEA values being 3.5–3.9 times and 4.0–4.7 times that of SCFT, respectively. Subsequently, parametric investigations underscored the evident influences of relative densities of T-TLS and foam filler, tube thickness and diameter on crashworthiness of foam-filled T-TLS. Finally, a multi-objective optimization was performed to derive optimized configurations by using non-dominated sorting genetic algorithm II (NSGA-II) and radial basis function (RBF) metamodels. In comparison with the baseline designs, the optimal results demonstrated significant enhancements in crashworthiness, with SEA increasing by 173.3 to 206.6 %. The present work provided a new paradigm in the design and development of advanced energy absorbers characterized by high-efficiency energy dissipation under lateral impact scenarios.
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