Hybridization between metals and thermoplastics allows manufacturers to create lightweight structures without compromising strength or performance. This innovative approach often leads to enhanced energy absorption capabilities, as the metals contribute ductility and toughness, which are critical for handling crash forces. Simultaneously, thermoplastics provide flexibility and ease of manufacturing, enabling complex shapes and designs to be produced more efficiently. In this context, this research aims to investigate the crashworthiness performance of 3D-printed polylactic acid (PLA) structures integrated within circular aluminum (Al) tubes. Special emphasis is placed on examining the influence of 3D printing parameters under quasi-static lateral loading conditions. To achieve this, three key printing parameters were each evaluated at four distinct levels: the infill pattern (gyroid, honeycomb, Schwarz P, and Schwarz D), infill density (5, 10, 20, and 30 %), and layer height (0.15, 0.20, 0.25, and 0.30 mm). Throughout this process, the data were systematically collected on the crash force, energy absorption, and displacement responses. Moreover, failure histories were recorded for each tube, offering insights into the structural failure progression and characteristics. The assessment of the crashworthiness performance was based on several critical metrics: total energy absorbed (U), specific energy absorption (SEA), and average crash force ( ). To identify the optimal configurations that enhance performance, a multi-attribute decision-making (MADM) approach called complex proportional assessment (COPRAS) was applied. The analysis indicated that a honeycomb pattern structure with 30 % infill density and a layer height of 0.20 mm, stuffed within an Al tube (referred to as Al/H30/0.20), provided optimum crashworthiness performance.