New European Collaboration Brings a 3D Printed Twist to Vehicle Safety Design

Researchers from both Scotland and Italy have announced a new type of 3D printed metamaterial that has the ability to transform the way vehicles absorb impact. The design has a unique twisting lattice structure and can adapt its response to collisions. These structures could be implemented in crumple zones, which are primarily located within the front of the vehicle and absorb the most impact in head-on collisions. This new metamaterial can potentially pave the way for safer and more efficient crash protection systems.

Developed using additive manufacturing, the adaptive twisting metamaterial features a precisely engineered gyroid lattice printed from steel. The design allows the structure to twist into itself under pressure, dispersing energy from an impact in a controlled manner. This level of responsiveness marks a significant step forward compared to traditional foams or crumple zones, which are limited to a single, fixed resistance profile.

A graphic showcasing the evolution from primative lattice to the new twisting metamaterial. (Photo Credit: University of Glasgow)

The research team, led by Professor Shanmugam Kumar from the University of Glasgow’s James Watt School of Engineering, demonstrated how the material’s behavior can be tuned by adjusting mechanical constraints during compression. In laboratory tests, the 3D-printed lattice could shift between stiff and flexible configurations, offering tailored energy absorption across different impact scenarios.