Increasing the impact resistance properties of any transport vehicle is a real engineering challenge. This challenge is addressed in this paper by proposing a high-performing structural solution. Hence, the performance, in terms of improvement of the energy absorbing characteristics and the reduction of the peak accelerations, of highly efficient shock absorbers integrated in key locations of a minibus chassis have been assessed by means of numerical crash simulations. The high efficiency of the proposed damping system has been achieved by improving the current design and manufacturing process of the state-of-the-art shock absorbers. Indeed, the proposed passive safety system is composed of additive manufactured, hybrid polymer/composite (Polypropylene/Composite Fibres Reinforced Polymers-PP/CFRP) shock absorbers. The resulting hybrid component combines the high stiffness-to-mass and strength-to-mass ratios characteristic of the composites with the capability of the PP to dissipate energy by plastic deformation. Moreover, thanks to the Additive Manufacturing (AM) technique, low-mass and low-volume highly-efficient shock-absorbing sandwich structures can be designed and manufactured. The use of high-efficiency additively manufactured sandwich shock absorbers has been demonstrated as an effective way to improve the passive safety of passengers, achieving a reduction in the peak of the reaction force and energy absorbed in the safety cage of the chassis' structure, respectively, up to up to 30 kN and 25%.
Keywords: additive manufacturing; composite materials; crashworthiness; finite elements; hybrid shock absorber.