This study investigates the axial crashworthiness of bio-inspired 3D-printed gyroid structure tubes with circular hole cuts. The crashworthiness of circular polylactic-acid (PLA) tubes with circular hole cuts was analyzed using quasi-static axial compression tests. Three design parameters—hole diameter (d), number of holes (n), and their positions (L)—were considered, with the Taguchi method used to optimize crashworthiness indicators. The results showed that the position (L) had the greatest impact on the initial peak crash force (Fip), while the hole diameter (d) had the most significant influence on energy absorption (U). The optimal parameters were confirmed through testing, showing that the designed tubes had a 30.48% lower Fip and 17.21% higher U compared to intact tubes. The study highlights the significant influence of holes on the crashworthiness performance of 3D-printed tubes. Crashworthiness is a critical aspect of vehicle design, focusing on enhancing safety and survivability by managing and absorbing energy during collisions. Crashworthy structures can be made from various materials, including steel, aluminum, and polymer composites. Thermoplastics, such as PLA, have gained attention due to their advantages like recyclability and cost-effectiveness. Additive manufacturing has enabled the production of complex cellular structures, with FDM being the most commonly used technique. Research has shown that the mechanical properties of 3D-printed cellular structures are significantly influenced by unit-cell configuration and infill patterns. Studies have also examined the crashworthiness of 3D-printed structures under quasi-static and dynamic loading conditions, revealing that the peak impact force increases with loading velocity, while specific energy absorption decreases. The study emphasizes the importance of optimizing design parameters to enhance crashworthiness performance in 3D-printed structures.This study investigates the axial crashworthiness of bio-inspired 3D-printed gyroid structure tubes with circular hole cuts. The crashworthiness of circular polylactic-acid (PLA) tubes with circular hole cuts was analyzed using quasi-static axial compression tests. Three design parameters—hole diameter (d), number of holes (n), and their positions (L)—were considered, with the Taguchi method used to optimize crashworthiness indicators. The results showed that the position (L) had the greatest impact on the initial peak crash force (Fip), while the hole diameter (d) had the most significant influence on energy absorption (U). The optimal parameters were confirmed through testing, showing that the designed tubes had a 30.48% lower Fip and 17.21% higher U compared to intact tubes. The study highlights the significant influence of holes on the crashworthiness performance of 3D-printed tubes. Crashworthiness is a critical aspect of vehicle design, focusing on enhancing safety and survivability by managing and absorbing energy during collisions. Crashworthy structures can be made from various materials, including steel, aluminum, and polymer composites. Thermoplastics, such as PLA, have gained attention due to their advantages like recyclability and cost-effectiveness. Additive manufacturing has enabled the production of complex cellular structures, with FDM being the most commonly used technique. Research has shown that the mechanical properties of 3D-printed cellular structures are significantly influenced by unit-cell configuration and infill patterns. Studies have also examined the crashworthiness of 3D-printed structures under quasi-static and dynamic loading conditions, revealing that the peak impact force increases with loading velocity, while specific energy absorption decreases. The study emphasizes the importance of optimizing design parameters to enhance crashworthiness performance in 3D-printed structures.