How do you design composite crash structures for energy absorption?

Composite crash structure design differs fundamentally from metal due to brittle failure mode. Energy absorption occurs through controlled fragmentation (crushing, delamination, fiber fracture) rather than plastic deformation. Design considerations include: Trigger mechanisms for stable crush initiation, fiber architecture affecting specific energy absorption (SEA), failure mode management (avoiding global buckling), progressive crushing maintenance, temperature and loading rate sensitivity, joint design to structure, and CAE modeling (progressive damage models). Testing characterizes SEA under various conditions. Composites can achieve higher SEA than metals but require careful design to ensure consistent, stable crushing behavior.