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A modified 3D re-entrant honeycomb is designed and fabricated utilizing Laser Cladding Deposition (LCD) technology, the mechanical properties of which are systematically investigated by experimental and finite element (FE) methods. Firstly, the influences of honeycomb angle on localized deformation and the response of force are studied by an experiment. Experimental results reveal that the honeycomb angles have a significant effect on deformation and force. Secondly, a series of numerical studies are conducted to analyze stress characteristics and energy absorption under different angles (α) and velocities (v). It is evident that two variables play an important role in stress and energy. Thirdly, response surface methodology (RSM) and the Non-Dominated Sorting Genetic Algorithm II (NSGA-II) are implemented with high precision to solve multi-objective optimization. Finally, the final compromise solution is determined based on the fitness function, with an angle of 49.23° and an impact velocity of 16.40 m/s. Through simulation verification, the errors of energy absorption (EA) and peak crush stress (PCS) are 9.26% and 0.4%, respectively. The findings of this study offer valuable design guidance for selecting the optimal design parameters under the same mass conditions to effectively enhance the performance of the honeycomb. [ABSTRACT FROM AUTHOR]

• A novel EARE is designed by introducing an elliptical annular into RE cell. • EARE produces extra vertical support without hindering lateral deformation. • EARE concurrently enhances auxetic performance, stiffness, and SEA. • Adjusting geometric parameters rationalizes designing mechanical properties. Auxetic structures have sparked a lot of interest due to their excellent mechanical characteristics and unusual negative Poisson's ratio influence. However, the large porosity property results in low stiffness, which limits their application scope. Current approaches to augment stiffness often result in diminished auxetic performance. Therefore, it is challenging to simultaneously enhance the auxetic, stiffness and energy absorption capacity of auxetic structures. To address this issue, this paper proposes a novel elliptical annular re-entrant honeycomb (EARE) by introducing an elliptical annular structure into a conventional re-entrant honeycomb (RE) cell, which can provide extra longitudinal support without hindering lateral deformation. The plateau stress, Poisson's ratio and energy absorption properties of the EARE are investigated by quasi-static compressive tests and finite element modeling. The results show that the EARE honeycomb has two plateau stages due to the supporting effect of the elliptical annular structure. Compared with the conventional RE honeycomb with the same wall thickness, the EARE honeycomb not only exhibits a stronger auxetic effect embodied in the Poisson's ratio reduced by 5.19%, but also has a higher average plateau stress and a higher specific energy absorption of 171.63% and 28.03%, respectively, which significantly improves the stiffness and energy absorption performance. The parameterized analysis reveals that by appropriately adjusting the geometric parameters, the stiffness, energy absorption, and auxetic effect of the EARE honeycomb can be enhanced. The research findings address the conflict between auxetic performance and honeycomb stiffness, providing new insights into the optimization of honeycomb structure design. [Display omitted] [ABSTRACT FROM AUTHOR]

• Metallic graded RECH prototypes fabricated through a low-cost step-by-step method. • Graded RECH takes advantage of structural hierarchy and functional gradient. • Gradient design causes multi-step deformation mode and multi-plateau stress. • Improved SEA and auxeticity of graded RECH under different crushing velocities. As lightweight energy-absorbing materials, auxetic honeycombs have demonstrated promising applications in engineering fields. In this study, the graded re-entrant circular auxetic honeycombs (RECH) were proposed, and their metallic prototypes were fabricated through a low-cost step-by-step method. The novel design of graded RECH takes advantage of structural hierarchy on the meso-scale and functional gradient on the macro-scale. The in-plane crushing behaviors of uniform (U) RECH, positive gradient (PG) RECH and negative gradient (NG) RECH with the same relative density were investigated under different crushing velocities. The finite element (FE) models were validated by comparing against the experimental and theoretical results. The results showed that the gradient design can control the multi-step deformation modes of RECH, which leads to the multi-plateau characteristics and reduced initial stress peaks in stress-strain curves. Under quasi-static crushing, the specific energy absorption (SEA) of PG-RECH is higher by 43.9% than that of U-RECH owing to more plastic deformations of hierarchical circular walls at a large strain. Under dynamic impacts, the SEA of NG-RECH is 2.7 times and 1.5 times those of PG-RECH and U-RECH at a small strain, respectively. Finally, the NG-RECH shows more negative Poisson's ratio (NPR) behavior than the U-RECH under dynamic crushing. This study offers new routes to the fabrication and design of auxetic metamaterials. [Display omitted] [ABSTRACT FROM AUTHOR]