Impact crushing response of additively manufactured hybrid metal-composite structures – A state of the art review

Abstract Thin-walled energy absorbing structures based on hybrid structural concepts have a lightweight benefit along with great potential of enhancing the crashworthiness characteristics. Inspired by the huge number of research investigations performed on novel additively manufactured hybrid metal-composite configurations and their latest developments, the current review article extensively reports the latest advances along with promising outcomes of the impact response of various additively manufactured hybrid metal-composite structures for crashworthiness applications. Specific consideration is given to the crushing performance of the hybrid structures fabricated from fused deposition modelling technique. The significant additive manufacturing techniques, their material selections and exceptional customized structural designs explored in recent times are discussed elaborately. Crushing patterns obtained by hybrid energy absorbing structures under various loading conditions are recognized. Furthermore, comparison of various hybrid structures and their latest advances revealed the efficiency of the thin-walled hybrid configuration based on 3D printing techniques in terms of weight reduction, crashworthiness and energy absorption behaviour. This review article will serve as a catalyst to boost the scientific improvement of hybrid energy absorbing structures utilized as passive safety protective devices in modern vehicles.