Background <p>Achieving stable deformation of lightweight thin-walled structures is the goal of the anti-collision energy field. Tube wall perforation and foam filling provide an effective approach for achieving the goal.</p> Objective <p>The objective of this paper is to realize adjustable mechanical properties and deformation of thin-walled tubes by optimizing the perforation shape and rate, the foam filling rate and the pore arrangement.</p> Methods <p>The effects of the perforation rate of negative Poisson’s ratio elliptical holes, the regular and staggered arrangement of positive Poisson’s ratio circular holes, and the number of foam filling layers on the mechanical response of stainless steel square tubes were experimentally studied. Additionally, samples with different elliptical distribution positions, foam filling rates, tube wall thicknesses, elliptical hole sizes and foam densities were simulated.</p> Results <p>Elliptical holes caused the square tube to exhibit an auxetic effect, while circular holes caused the square tube to protrude outwards. The foam filling alleviated the unstable deformation of the square tubes with circular holes. The distribution of elliptical holes had a great influence on the deformation behaviour. Increasing the thickness of the elliptical hole tube wall and decreasing the thickness of the solid tube wall stabilised the deformation and mechanical properties of the sample. Small elliptical holes and high-density foam can improve the sample properties.</p> Conclusions <p>Through structural design, the mechanical properties and deformation behaviour of thin-walled square tubes can be effectively controlled to meet different application requirements.</p>