A joint research team led by the University of Glasgow, together with Italy’s Polytechnic University of Marche, University of L’Aquila, and the National Institute for Nuclear Physics, has developed a 3D-printed twisting metamaterial designed for impact absorption in automotive and aerospace safety systems, reports 3D Printing Industry blog.
Unlike typical crash materials (foams or fixed crumple zones) that offer a constant resistance profile, this steel lattice uses a gyroid unit cell architecture that physically twists like a corkscrew when compressed. That twist transforms linear force into rotational deformation, tuning energy-absorption characteristics mechanically rather than electronically or hydraulically.
In laboratory tests, three configurations were explored: one where the lattice was prevented from twisting (maximizing stiffness), one where free twisting was allowed (moderate absorption) and another where over-twisting was forced (reduced absorption). The maximum achieved energy absorption was about 15.36 J/g in the constrained condition. Allowing free twist reduced absorption by ~10%; over-twisting cut it by ~33%.
The ability to mechanically adjust between stiffer or softer responses means that one material block could serve for light-impact cushioning or rigid crash shielding, depending on circumstances. That adaptability opens doors for smarter protective structures without added electronics.
For engineers in automotive design and additive manufacturing, key implications are: (1) additive manufacturing (AM) enables architectures such as gyroid lattices not possible via conventional methods; (2) materials can be designed with tunable mechanical response built in; (3) future safety systems might integrate these metamaterials as part of intelligent crash zones or energy-harvesting components. However, real-world deployment will require validation under full-scale, real-world loads and production-compatible AM processes.
This research represents a meaningful step toward truly adaptive safety materials, moving beyond static protection to structures that respond and evolve under impact.