Recent Advances in Additively Manufactured Polymeric Structures for Mechanical Energy Absorption

Additive manufacturing has emerged as a powerful approach for producing architected materials with tailored mechanical properties and enhanced energy absorption capabilities. By enabling precise control over geometry, relative density, and hierarchical topology, additive manufacturing facilitates the design of lightweight cellular structures with superior crashworthiness compared to conventional energy-absorbing materials. This review provides a comprehensive overview of recent advances in additively manufactured energy-absorbing structures, with particular emphasis on the interplay between structural architecture, fabrication technologies, and mechanical performance. Key additive manufacturing processes, including fused deposition modeling, stereolithography, selective laser sintering, and multi-jet fusion, are evaluated in terms of their fabrication capabilities, material compatibility, and inherent limitations. Special attention is given to the mechanical behavior of representative architectures, including two-dimensional cellular structures, three-dimensional lattice geometries, sandwich systems, and emerging four-dimensional programmable materials. Depending on topology and material system, additively manufactured lattices can achieve specific energy absorption values exceeding 20–40 J g−1, significantly outperforming many conventional foams. Finally, current challenges, such as process-induced defects, anisotropic mechanical behavior, and the lack of standardized testing methodologies, are discussed, along with future research directions, including multi-material printing, functionally graded architectures, and adaptive metamaterials for next-generation impact mitigation systems.