Performance evaluation of lattice structured bumper beam for automobile

Bumper beam performance and design are critical to vehicle safety, structural integrity, and environmental sustainability. We analyzed lattice-structured bumper beams and explained how they can be designed to address issues associated with traditional solid systems. For instance, bumper beams made of conventional steel and aluminium contribute to increased vehicle weight, which negatively impacts fuel economy. We explored lattice geometries, particularly octet lattice structures, using advanced materials and novel additive manufacturing techniques to mitigate these issues. In this study, lattice-structured auto bumper beams were designed to possess octet truss geometries, which were then subjected to finite element analysis (FEA). This was intended to lower component weight and enhance energy absorption from traditional solid bumpers. Structural steel and carbon fiber reinforced polymer (CFRP) bumper designs were simulated using lattice and solid, and the material was set as the material of FEA. It was demonstrated that, in the lattice configuration, a weight reduction of 88.2% and significantly higher energy absorption are possible. The numerical results demonstrated positive findings; however, it is suggested that experimental testing be conducted in future investigations. It was shown that lattices and additive manufacturing can enable sustainable high-performance vehicle components. The conclusions emphasized the advantages of advanced materials, such as carbon fiber-reinforced plastic, which offer high impact resistance and lightweight properties. Furthermore, adaptive manufacturing ensures precise material distribution, minimizes waste, and enhances cost efficiency. These findings underscore the potential of forged lattice designs in vehicle safety systems, improving crashworthiness, reducing greenhouse gas emissions, and aligning with sustainable manufacturing principles. We identified forged-lattice bumper beams as a transformative innovation for next-generation motor vehicle components, leading to safer, lighter, and more environmentally friendly automobiles. © 2025 Elsevier B.V., All rights reserved.