In this study, novel tetra-chiral spline missing-rib structure is designed and experimentally tested to enhance energy-absorbing in crash conditions. Out-of-plane quasi-static compression tests are carried out for both classical and novel missing-rib structures made with additive manufacturing. The numerical models are created and required details are used to predict the energy absorption (EA) of structures. Two criteria namely, energy absorption efficiency and deformation efficiency are examined to determine the EA of the structures. By using these criteria, the numerical finite element analysis is validated and calibrated with the test experiments. Then based on Response Surface Methodology (RSM), design of experiments (DOE) is carried out compression analysis are modeled using FEA. For optimization, four regression models are examined and 2FI model is chosen. Then by maximizing energy absorption, optimum geometrical parameters are determined. Finally, the optimal model is constructed and FEM results are verified again. Great enhancement in energy absorption capacity of the novel missing-rib is substantial which can be served by designers as basis for future lightweight structures.
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