Compressive Properties of Functionally Graded Bionic Bamboo Lattice Structures Fabricated by FDM

Gradient lattice structures are gaining increased attention due to better meeting the crashworthiness requirements of lightweight structures. This study explores how cell number, configuration, and diameter ratio affect mechanical properties and energy absorption. Three new types of gradient lattice structures are designed. Initially, the mechanical properties, deformation behaviors, and energy absorption capabilities of gradient lattice structures are analyzed through finite element simulations. Subsequently, gradient lattice structures are fabricated using 316L laser powder bed fusion technology, and quasistatic compression tests are conducted using a materials testing machine to validate the effectiveness of the simulation results. The results show that the inner and outer structure diameter ratio gradient strategy has the greatest influence on the mechanical properties and energy absorption capacity of the lattice structure. Among all the gradient structures, the BSF structure (cell number gradient lattice structure‐F) is the optimal structure, whose maximum impact force and total energy absorption are 88.8 and 107.9% higher than those of the conventional uniform JYC structure (uniform gradient lattice structure‐C), respectively. The three gradient strategies proposed in this study provide insights into the design and optimization of impact‐resistant lattice structures, which can be used as potential materials for future impact‐resistant applications.

Crashworthiness and stiffness improvement of a variable cross-section hollow BCC lattice reinforced with metal strips

Generative design and mechanical properties of the lattice structures for tensile and compressive loading conditions fabricated by selective laser melting

Mechanical properties and energy absorption of 3D printed double-layered helix honeycomb under in-plane compression

Topology optimization for concurrent design of layer-wise graded lattice materials and structures

The design of lightweight lattice structures with excellent specific mechanical properties has received great attention in recent years. In this paper, inspired by the hierarchical structure of biological materials, a novel hierarchical circular-cell configuration of a lattice structure was proposed. The advantage of the new lattice configuration is that the use of a smooth circular cell is able to alleviate the stress concentration induced by the intersection of straight struts. Additionally, the consideration of structural hierarchy can bring improved mechanical properties of lattice structures. The hierarchical circular lattice structures with 5 × 5 × 5 unit cells were fabricated through a digital light processing (DLP) 3D printer, using the hard-tough resin. The mechanical properties of the lattice structures were investigated by a compression experiment and a numerical simulation. Results show that the interaction effect of structural hierarchy was the potential mechanism for the enhancement of mechanical properties. The designed hierarchical circular-cell lattice structure exhibits improved stress distribution uniformity, enhanced mechanical performance, and energy absorption capacity. The maximum improvement values are ~342.4% for specific stiffness, ~13% for specific strength, ~126.6% for specific energy absorption (SEA), and ~18% for crash load efficiency (CLE). The developed hierarchical circular-cell lattice configuration will enrich the present lattice systems and be useful for future multifunctional applications.

Metallic lattice structures have been widely utilized in different fields such as automobile, aerospace and so on, owing to their superior mechanical properties and energy absorption characteristics. In this paper, the enhanced dynamic mechanical properties of the modified rhombic dodecahedron (RD) lattice structures were investigated systematically through numerical simulation and theoretical analysis. Results indicated that compressive modulus, initial yield strength and normalized specific energy absorption (SEA) of the modified RD lattice structures all exhibited a quadratic growth trend with the increase of relative density beyond following the traditional law. Meanwhile, the plateau stress and normalized SEA exhibited certain sensitivity to the strain rate and almost linearly increased as the loading rate increased. Finally, a modified rigid-perfectly plastic-locking shock wave model was also proposed, and the predicted results of the proposed modified shock wave model were consistent with the simulation results.

Crashworthiness improvements of multi-cell thin-walled tubes through lattice structure enhancements

In-plane crushing behavior and energy absorption of sponge-inspired lattice structures

The applications of triply periodic minimum surfaces (TPMS) in biomedicine, aerospace and functionally graded materials have garnered significant interest. In order to further explore the possibility of regulating the properties of TPMS-based lattice structures, radial-graded Gyroid lattice structures (GLSs) were constructed and Al–Si10–Mg samples were prepared by selective laser melting (SLM). FEA and compression experiments were employed to evaluate the deformation behavior, mechanical response and energy absorption of GLSs. The introduction of the Johnson–Cook model effectively simulated the deformation and failure mechanism of G-777 and G-791, and both of them showed uniform deformation. In comparison to G-777, G-791 demonstrated enhancements of 19.234%, 33.096%, 49.729% and 15.421% in yield strength, plateau stress, elastic modulus and energy absorption, respectively. Meanwhile, the numerical simulation results were in good agreement with the experimental results. The present study suggests the mechanical properties and energy absorption capacity of GLSs can be regulated by radial gradient. This paper can provide a theoretical foundation for customizing the performance of TPMS-based lattice structures.

Numerical and experimental studies on compressive behavior of Gyroid lattice cylindrical shells

Additively manufactured materials and structures: A state-of-the-art review on their mechanical characteristics and energy absorption

This study investigates the quasi-static and dynamic crushing behavior of a bio-inspired cactus geometry core structure manufactured from ABS polymer using fused deposition modeling. The mechanical response and energy absorption characteristics of the structure were examined experimentally under a wide range of strain rates, including quasi-static compression, drop-weight, and direct impact Split Hopkinson Pressure Bar (SHPB) tests. Corresponding finite element models were developed in LS-DYNA using the piecewise linear plasticity material model with Cowper–Symonds rate sensitivity parameters calibrated from material characterization tests. The experimental and numerical results showed close agreement in both quasi-static and dynamic regimes. Increasing loading rate led to higher initial peak forces and energy absorption values, while delaying the onset of folding. The strain-rate and inertial contributions to the crushing response were quantitatively separated, revealing that inertia dominated in the early elastic region, whereas strain-rate effects governed the plastic deformation stage. The cactus-inspired core exhibited stable deformation and significant energy dissipation, indicating its potential as a lightweight protective component in impact and crashworthiness applications.

Mechanisms of low-frequency bandgap formation and energy absorption of three-dimensional nested hybrid lattice structures

Experimental investigation on energy absorption of auxetic structures