Search Results (20)

Lattice-based metamaterials have attracted much attention due to their excellent mechanical properties. Nevertheless, designing lattice materials with desired properties is still challenging, as their mesoscopic topology is extremely complex. Herein, the bidirectional evolutionary structural optimization (BESO) method is adopted to design lattice structures with maximum bulk modulus and elastic isotropy. Various lattice configurations are generated by controlling the filter radius during the optimization processes. Afterwards, the optimized lattices are fabricated using Stereo Lithography Appearance (SLA) printing technology. Experiments and numerical simulations are conducted to reveal the mechanical behavior of the topology-optimized lattices under quasi-static compression, which are compared with the traditional octet-truss (OT) and body-centered cubic (BCC) lattice structures. The results demonstrate that the topology-optimized lattices exhibited superior mechanical properties, including modulus, yield strength, and specific energy absorption, over traditional OT and BCC lattices. Moreover, apart from the elastic modulus, the yield stress and post-yield stress of the topology-optimized lattice structures with elastically isotropic constraints also present lower dependence on the loading direction. Accordingly, the topology optimization method can be employed for designing novel lattice structures with high performance. Full article

This work focuses on characterizing structured metamaterials by assessing their elastic law and ultimate strength using finite elements and limit analysis applied to a representative volume element. The elastic and plastic behavior of a reference geometry—the octet truss lattice—is obtained by calculating the response of the representative volume element subjected to prescribed tensor strain bases, namely pure normal strain and pure shear, along the cube symmetry directions. The geometry of the body centered cubic and pure cubic phases of the representative volume element has been analyzed, highlighting that the elastic isotropic behavior depends on the ratio between the stiffnesses of the two phases. The ultimate behavior of the structure has been analyzed through the direct application of the lower bound method of limit analysis. The method has been implemented in a direct finite element environment using the limit analysis procedure developed by the authors. The method was already used and described in previous publications and is briefly recalled. It is based on the identification of the linear operator linking the self-equilibrated stress set to a discrete parameter manifold, accounting for the piecewise continuous distribution of the permanent strain. In the paper, it is highlighted that for different aspect ratios between the body-centered cubic and the pure cubic phase geometry, different ratios between limit shear stress and normal stress arise, the isotropic one assumed to coincide with the von Mises result, where ${\displaystyle \frac{{\sigma }_0}{{\tau }_0}}=\sqrt{3}$. Full article

Cellular structures, formed by periodic two- or three-dimensional cells, offer weight reduction without compromising mechanical performance and are commonly fabricated via additive manufacturing. This study investigates the compressive behaviour of three polymer lattice structures—gyroid, diamond, and octet truss—fabricated by fused filament fabrication (FFF). A Box–Behnken experimental design was used to systematically evaluate the influence of three key parameters: cell size, strut/wall thickness, and layer thickness. A total of 225 samples were produced using PLA and subjected to compression testing in accordance with ASTM D1621. Linear regression and response surface methodology were employed to determine the statistical significance and impact of each factor. The results indicate that cell size has the strongest influence on both maximum force and displacement, followed by strut/wall thickness and layer thickness. Among the configurations, gyroid structures had the highest strength-to-density ratio, while diamond structures had the highest deformation capacity. These findings provide design insights for optimising lattice structures in lightweight applications and highlight the importance of carefully balancing geometric and printing parameters in FFF-based polymer components. Full article

In this study, the effect of high temperature on the mechanical performance of CoCrNi medium-entropy alloy octet-truss lattice material fabricated via laser powder bed fusion (LPBF) is investigated by compressive test and numerical simulation method. The results reveal that the strength and energy absorption performance of CoCrNi octet-truss lattice material with a hollow truss are higher than those of ones with a solid truss; however, they diminish by 30% and 50%, respectively, as temperature rises from 25 °C to 600 °C. As the temperature rises, the potential barrier for dislocation slip decreases, making it easier for dislocations to move at high temperatures and thus reducing the strength. CoCrNi octet-truss lattice materials present the failure mechanism of progressive collapse at varied temperatures. Meanwhile, the mechanical performance of the experimental testing agreed well with numerical simulation results. The numerical results show that the strength and energy absorption properties of the CoCrNi lattice materials increase as the relative density, however, decreases with increasing temperature. Additionally, CoCrNi octet-truss lattice materials maintain exceptional energy absorption performance at varied temperatures. Full article

This study investigates the underwater explosion resistance of aluminum alloy octet-truss lattice sandwich structures using shock tube experiments and LS-DYNA simulations. A systematic analysis reveals key mechanisms influencing protective performance. The sandwich configuration mitigates back plate displacement through quadrilateral inward deformation, exhibiting phased deformation responses between face plates and back plates mediated by lattice interactions. Increasing the lattice relative density from 0.1 to 0.3 reduces maximum back plate displacement by 22.2%. While increasing the target plate thickness to 1.5 mm reduces displacement by 47.6%, it also decreases energy absorption efficiency by 20% due to limited plastic deformation. Fluid–structure interaction simulations correlate well with 3D-DIC deformation measurements. The experimental results demonstrate the exceptional impact energy absorption capacity of the octet-truss lattice and highlight the importance of stiffness-matching strategies for enhanced energy dissipation. These findings provide valuable insights for optimizing the design of underwater protection structures. Full article

Cellular biomaterials offer unique properties for diverse biomedical applications. However, their complex viscoelastic behavior requires careful consideration for design optimization. This study explores the effective viscoelastic response of two promising unit cell designs (tetrahedron-based and octet-truss) suitable for high porosity and strong mechanics. The asymptotic homogenization (AH) method was employed to determine effective longitudinal and shear moduli, as well as Poisson’s ratio, across various relative densities. Finite element simulations (ABAQUS) validated the AH results, demonstrating good agreement (<10% discrepancies). Additionally, analytical models and compression tests on 3D-printed lattice structures supported the theoretical predictions. The study revealed a strong correlation between relative density and the effective modulus of both designs. Notably, the tetrahedron-based design exhibited superior modulus, making it favorable for high loading levels, particularly when used as a high-density configuration. Both designs demonstrated minimal time-dependent elastic modulus changes and a near-constant Poisson’s ratio (0.34–0.349 for octet-truss, 0.316–0.326 for tetrahedron) across a 5–50% relative density range. While minimal, time-dependent modulus reduction needs to be considered in longer-term simulations ($t>{10}^7$ $\mathrm{s}$). This study provides valuable insights into the viscoelastic behavior of these unit cells using the homogenization method, with potential applications in various biomedical fields. Full article

This study investigates the design of additive manufacturing for controlled crack propagation using process parameters and lattice structures. We examine two lattice types—octet-truss (OT) and diamond (DM)—fabricated via powder bed fusion with Ti-6Al-4V. Lattice structures are designed with varying densities (10%, 30%, and 50%) and process using two different laser energies. Using additive-manufactured specimens, Charpy impact tests are conducted to evaluate the fracture behavior and impact energy levels of the specimens. Results show that the type of the lattice structures, the density of the lattice structures, and laser energy significantly influence crack propagation patterns and impact energy. OT exhibits straighter crack paths, while DM demonstrates more random fracture patterns. Higher-density lattices and increased laser energy generally improve the impact energy. DM consistently outperformed OT in the impact energy for angle specimens, while OT showed superior performance in stair specimens. Finally, a case study demonstrates the potential for combining OT and DM structures to guide crack propagation along predetermined paths, offering a novel approach to protect critical components during product failure. Full article

In this study, we present the energy absorption capabilities achieved through the application of hybrid lattice structures, emphasizing their potential across various industrial sectors. Utilizing Ti-6Al-4V and powder bed fusion (PBF) techniques, we fabricated distinct octet truss, diamond, and diagonal lattice structures, tailoring each to specific densities such as 10, 30, and 50%. Furthermore, through the innovative layering of diverse lattice types, we introduced hybrid lattice structures that effectively overcome the inherent energy absorption limitations of single-lattice structures. As a result, we conducted a comprehensive comparison between single-lattice structures and hybrid lattice structures of equal density, unequivocally showcasing the latter’s superior energy absorption performance in terms of compression. The single-lattice structure, OT, showed an energy absorption of 42.6 J/m³, while the reinforced hybrid lattice structure, OT-DM, represented an energy absorption of 77.8 J/m³. These findings demonstrate the significant potential of hybrid lattice structures, particularly in energy-intensive domains such as shock absorption structures. By adeptly integrating various lattice architectures and leveraging their collective energy dissipation properties, hybrid lattice structures offer a promising avenue for addressing energy absorption challenges across diverse industrial applications. Full article

The dual-phase lattice structure composed of the matrix phase (MP) and the reinforcement phase (RP) is a novel hybrid lattice showing excellent energy absorption ability. However, the mechanical behavior of the dual-phase lattice structure under dynamic compression and the enhancement mechanism of the reinforcement phase have not been widely studied with the increase in compression speed. Based on the design requirements of dual-phase lattice materials, this paper combined octet-truss cell structures with different porosities, and the dual-density hybrid lattice specimens were fabricated via the fused deposition modeling technique. Under quasi-static and dynamic compressive loadings, the stress–strain behavior, energy absorption capacity, and deformation mechanism of the dual-density hybrid lattice structure were studied. The results showed that the quasi-static-specific energy absorption of the dual-density hybrid lattice structure was significantly higher than that of the single-density Octet lattice, and with the increase in compression strain rate, the effective specific energy absorption of the dual-density hybrid lattice structure also increased. The deformation mechanism of the dual-density hybrid lattice was also analyzed, and the deformation mode changed from an inclined deformation band to a horizontal deformation band when the strain rate changed from 10⁻³ s⁻¹ to 100 s⁻¹. Full article

Metal lattice structures manufactured utilising additive techniques are attracting increasing attention thanks to the high structural efficiency they can offer. Although many studies exist on the characterisation of massive parts in Ti6Al4V processed by Electron Beam Melting (EBM), several investigations are necessary to characterise the Ti6Al4V lattice structures made by the EBM process. The objective of this paper is to develop a measurement method to assess the dimensional accuracy of Ti6Al4V octet truss lattice structures manufactured by EBM technology. Beam specimens with a 2 mm diameter and different growth orientations with respect to the build direction were analysed. The geometry differences between the designed and the manufactured beam specimens were highlighted. Two effects were identified: (i) The EBM-manufactured beams are generally thinner than the designed ones, and (ii) the shape of the section was found to be almost circular for the beam specimens oriented at 45° and 90°; on the contrary, the section of the horizontal beam (0°) cannot be considered circular. Full article

We investigate the compressive energy absorption performance of polymeric octet-truss lattice structures that are 3D printed using high-resolution stereolithography. These structures are potential candidates for personal protective equipment, structural, and automotive applications. Two polymeric resins (high-strength/low-ductility and moderate-strength/high-ductility) were used in this work, and a comprehensive uniaxial tensile characterization was conducted to establish an optimal UV curing time. The external octet-truss structure geometry (3″ × 3″ × 3″) was maintained, and four different lattice cell densities (strut length, L) and three different strut radii (R) were printed, UV cured, and compression tested. The compressive stress–strain and energy absorption (EA) behavior were quantified, and the EA at 0.5 strain for the least dense and smallest R structure was 0.02 MJ/m³, while the highest density structure with the largest R was 1.80 MJ/m³ for Resin 2. The structural failure modes varied drastically based on resin type, and it was shown that EA and deformation behavior were related to L, R, and the structures’ relative density ($\overline{\rho }$). For the ductile resin, an empirical model was developed to predict the EA vs. compressive strain curves based on L and R. This model can be used to design an octet-truss lattice structure based on the EA requirements of an application. Full article

Cellular lattices with architectural intricacy or metamaterials have gained a substantial amount of attention in the past decade due to the recent advances in additive manufacturing methods. The lattice topology controls its physical and mechanical properties; therefore, the main challenge is selecting the appropriate lattice topology for a desired function and application. In this work, we comprehensively study the topology–property relationship of three classes of polymer metamaterials based on triply periodic minimal surfaces (TPMS) of sheet/shell and ligament types, and other types of well-known strut-based lattices. The study uses a holistic approach of designing, additive manufacturing, microstructural characterization, and compressive uniaxial mechanical testing of these polymer lattices that are 3D-printed using the laser powder bed fusion technique known as selective laser sintering (SLS). In total, 55 lattices with different topologies and relative densities were 3D-printed and tested. Printing quality was assessed using scanning electron microscopy and micro-computed tomography. The extracted mechanical properties of elastic modulus, yield strength, plateau strength, and energy absorption are thoroughly compared between the different lattice architectures. The results show that all the investigated ligament-based TPMS polymer lattices exhibit bending-dominated elastic and plastic behavior, indicating that they are suitable candidates for energy absorbing applications. The sheet-based TPMS polymer lattices, similarly to the well-known Octet-Truss lattice, exhibited an elastic stretching-dominated mode of deformation and proved to have exceptional stiffness as compared to all other topologies, especially at low relative densities. However, the sheet-based TPMS polymer lattices exhibited a bending-dominated plastic behavior which is mainly driven by manufacturing defects. Overall, however, sheet-based TPMS polymer lattices exhibited the best mechanical properties, followed by strut-based lattices and finally by ligament-based TPMS lattices. Finally, it is depicted that at high relative densities, the mechanical properties of lattices of various architectures tend to converge, which implies that the topological effect is more significant at low relative densities. Generally, this study provides important insights about the selection of polymer mechanical metamaterials for various applications, and shows the superiority of TPMS-based polymer metamaterials as compared to several other classes of polymer mechanical metamaterials. Full article

Engineered lattice structures fabricated via additive manufacturing (AM) technologies are of great interest for many applications that require high strength and/or stiffness with minimum mass. This paper studies a novel axial lattice extrusion (ALE) AM technique that greatly enhances mechanical properties of polymeric lattice structures. When the novel ALE process was used to produce 84 mm × 84 mm × 84 mm octet truss lattice samples using fiber reinforced ABS, a total of 219,520 polymer interfaces in the lattice beams were eliminated relative to the conventional 3D printing alternative. Microscopic examination revealed near perfect alignment of the chopped carbon fibers with axes of the cylindrical beams that make up the lattice structure. The greatly enhanced beam quality with fiber reinforcement resulted in excellent mechanical properties. Compression testing yielded an average relative compressive strength of 17.4 MPa and an average modulus of 162.8 MPa. These properties rate very strongly relative to other published work, and indicate that the ALE process shows great potential for fabrication of high-strength, lightweight, large-scale, carbon-fiber composite components. The paper also contributes a modeling approach to finite element analysis (FEA) that captures the highly orthotropic properties of carbon fiber lattice beams. The diagonal shear failure mode predicted via the FEA model was in good agreement with experimentally observed results. Full article

Vibration fatigue characteristics are critical for rotating machinery components such as turbine rotor blades. Lattice structures are gaining popularity in engineering applications due to their unique ability to reduce weight and improve the mechanical properties. This study is an experimental investigation of octet-truss lattice structure utilization in turbine rotor blades for weight reduction and to improve vibration fatigue characteristics. One completely solid and three lattice infilled blades with variable strut thickness were manufactured via additive manufacturing. Both free and forced experimental vibration analyses were performed on the blades to investigate their modal and vibration fatigue characteristics. The blades were subjected to random vibration using a vibration shaker. The response was measured using a triaxial accelerometer in terms of vibration acceleration time histories in the X, Y, and Z directions. Results indicate a weight reduction of up to 24.91% and enhancement in the first natural frequency of up to 5.29% were achieved using lattice infilled blades. The fatigue life of the blades was investigated using three frequency domain approaches, namely, Lalanne, Dirlik and narrow band. The fatigue life results indicate that the 0.25 mm lattice blade exhibits the highest fatigue life, while the solid blade exhibits the lowest fatigue life of all four blades. The fatigue life of the 0.25 mm lattice blade was 1822-, 1802-, and 1819- fold higher compared to that of the solid blade, using the Lalanne, Dirlik, and narrow-band approaches, respectively. These results can serve as the first step towards the utilization of lattice structures in turbine blades, with thermal analysis as the next step. Therefore, apart from being light weight, the octet-truss lattice infilled blades exhibited superior vibration fatigue characteristics to vibration loads, thereby making them a potential replacement for solid blades in turbine rotors. Full article

Lightweight reactor materials that simultaneously possess low heat capacity and large surface area are desirable for various applications such as catalytic supports, heat exchangers, and biological scaffolds. However, they are challenging to satisfy this criterion originating from their structural property in most porous cellular solids. Microlattices have great potential to resolve this issue in directing transport phenomena because of their hierarchically ordered design and controllable geometrical features such as porosity, specific surface, and tortuosity. In this study, we report hollow ceramic microlattices comprising a 10 μm thick hollow nickel oxide beam in an octet-truss architecture with low heat capacity and high specific surface area. Our microarchitected reactors exhibited a low heat capacity for a rapid thermal response with a small Biot number (Bi << 1) and large intertwined surface area for homogeneous flow mixing and chemical reactions, which made them ideal candidates for various energy applications. The hollow ceramic microlattice was fabricated by digital light three-dimensional (3D) printing, composite electroless plating, polymer removal, and subsequent thermal annealing. The transient thermal response and fluidic properties of the 3D-printed microstructures were experimentally investigated using a small-scale thermal and fluid test system, and analytically interpreted using simplified models. Our findings indicate that hollow microarchitected reactors provide a promising platform for developing multifunctional materials for thermal and fluid applications. Full article