Micromechanics of Amorphous Metal/Polymer Hybrid Structures with 3D Cellular Architectures: Size Effects, Buckling Behavior, and Energy Absorption Capability

Design, Manufacturing, and Analysis of Periodic Three-Dimensional Cellular Materials for Energy Absorption Applications: A Critical Review

Cellular materials offer industries the ability to close gaps in the material selection design space with properties not otherwise achievable by bulk, monolithic counterparts. Their superior specific strength, stiffness, and energy absorption, as well as their multi-functionality, makes them desirable for a wide range of applications. The objective of this paper is to compile and present a review of the open literature focusing on the energy absorption of periodic three-dimensional cellular materials. The review begins with the methodical cataloging of qualitative and quantitative elements from 100 papers in the available literature and then provides readers with a thorough overview of the state of this research field, discussing areas such as parent material(s), manufacturing methods, cell topologies, cross-section shapes for truss topologies, analysis methods, loading types, and test strain rates. Based on these collected data, areas of great and limited research are identified and future avenues of interest are suggested for the continued maturation and growth of this field, such as the development of a consistent naming and classification system for topologies; the creation of test standards considering additive manufacturing processes; further investigation of non-uniform and non-cylindrical struts on the performance of truss lattices; and further investigation into the performance of lattice materials under the impact of non-flat surfaces and projectiles. Finally, the numerical energy absorption (by mass and by volume) data of 76 papers are presented across multiple property selection charts, highlighting various materials, manufacturing methods, and topology groups. While there are noticeable differences at certain densities, the graphs show that the categorical differences within those groups have large overlap in terms of energy absorption performance and can be referenced to identify areas for further investigation and to help in the preliminary design process by researchers and industry professionals alike.

Crashworthiness of 3D Lattice Topologies under Dynamic Loading: A Comprehensive Study

Periodic truss-based lattice materials, a particular subset of cellular solids that generally have superior specific properties as compared to monolithic materials, offer regularity and predictability that irregular foams do not. Significant advancements in alternative technologies-such as additive manufacturing-have allowed for the fabrication of these uniquely complex materials, thus boosting their research and development within industries and scientific communities. However, there have been limitations in the comparison of results for these materials between different studies reported in the literature due to differences in analysis approaches, parent materials, and boundary and initial conditions considered. Further hindering the comparison ability was that the literature generally only focused on one or a select few topologies. With a particular focus on the crashworthiness of lattice topologies, this paper presents a comprehensive study of the impact performance of 24 topologies under dynamic impact loading. Using steel alloy parent material (manufactured using Selective Laser Melting), a numerical study of the impact performance was conducted with 16 different impact energy-speed pairs. It was possible to observe the overarching trends in crashworthiness parameters, including plateau stress, densification strain, impact efficiency, and absorbed energy for a wide range of 3D lattice topologies at three relative densities. While there was no observed distinct division between the results of bending and stretching topologies, the presence of struts aligned in the impact direction did have a significant effect on the energy absorption efficiency of the lattice; topologies with struts aligned in that direction had lower efficiencies as compared to topologies without.

Mechanical Characterization of Multifunctional Metal-Coated Polymer Lattice Structures

Metal-coated lattice structures hold significant promise for customizing mechanical properties in diverse industrial applications, including the mechanical arms of unmanned aerial vehicles. However, their intricate geometries pose computational challenges, resulting in time-intensive and costly numerical evaluations. This study introduces a parameterization-based multiscale method to analyze body-centered cubic lattice structures with metal coatings. We establish the validity and precision of our proposed method with a comparative analysis of numerical results at the Representative Volume Element (RVE) scale and experimental findings, specifically addressing both elastic tensile and bending stiffness. Furthermore, we showcase the method's accuracy in interpreting the bending stiffness of coated lattice structures using a homogenized material-based solid model, underscoring its effectiveness in predicting the elastic properties of such structures. In exploring the mechanical characterization of coated lattice structures, we unveil positive correlations between elastic tensile stiffness and both coating thickness and strut diameter. Additionally, the metal coating significantly enhances the structural elastic bending stiffness multiple times over. The diverse failure patterns observed in coated lattices under tensile and bending loads primarily stem from varied loading-induced stress states rather than external factors. This work not only mitigates computational challenges but also successfully bridges the gap between mesoscale RVE mechanical properties and those at the global structural scale.

Polymer Composites in 3D/4D Printing: Materials, Advances, and Prospects

Additive manufacturing (AM), commonly referred to as 3D printing, has revolutionized the manufacturing landscape by enabling the intricate layer-by-layer construction of three-dimensional objects. In contrast to traditional methods relying on molds and tools, AM provides the flexibility to fabricate diverse components directly from digital models without the need for physical alterations to machinery. Four-dimensional printing is a revolutionary extension of 3D printing that introduces the dimension of time, enabling dynamic transformations in printed structures over predetermined periods. This comprehensive review focuses on polymeric materials in 3D printing, exploring their versatile processing capabilities, environmental adaptability, and applications across thermoplastics, thermosetting materials, elastomers, polymer composites, shape memory polymers (SMPs), including liquid crystal elastomer (LCE), and self-healing polymers for 4D printing. This review also examines recent advancements in microvascular and encapsulation self-healing mechanisms, explores the potential of supramolecular polymers, and highlights the latest progress in hybrid printing using polymer-metal and polymer-ceramic composites. Finally, this paper offers insights into potential challenges faced in the additive manufacturing of polymer composites and suggests avenues for future research in this dynamic and rapidly evolving field.

Starfish-Inspired Diamond-Structured Calcite Single Crystals from a Bottom-up Approach as Mechanical Metamaterials

Inspired by knobby starfish, this work demonstrates a bottom-up approach for fabricating a calcite single-crystal (CSC) with a diamond structure by exploiting the self-assembly of the block copolymer and corresponding templated synthesis. Similar to the knobby starfish, the diamond structure of the CSC gives rise to a brittle-to-ductile transition. Most interestingly, the diamond-structured CSC fabricated exhibits exceptional specific energy absorption and strength with lightweight character superior to natural materials and artificial counterparts from a top-down approach due to the nanosized effect. This approach provides the feasibility for creating mechanical metamaterials with the combined effects of the topology and nanosize on the mechanical performance.

Three dimensional architected thermoelectric devices with high toughness and power conversion efficiency

For decades, the widespread application of thermoelectric generators has been plagued by two major limitations: heat stagnation in its legs, which limits power conversion efficiency, and inherent brittleness of its constituents, which accelerates thermoelectric generator failure. While notable progress has been made to overcome these quintessential flaws, the state-of-the-art suffers from an apparent mismatch between thermoelectric performance and mechanical toughness. Here, we demonstrate an approach to potentially enhance the power conversion efficiency while suppressing the brittle failure in thermoelectric materials. By harnessing the enhanced thermal impedance induced by the cellular architecture of microlattices with the exceptional strength and ductility (>50% compressive strain) derived from partial carbonization, we fabricate three-dimensional (3D) architected thermoelectric generators that exhibit a specific energy absorption of ~30 J g^-1 and power conversion efficiency of ~10%. We hope our work will improve future thermoelectric generator fabrication design through additive manufacturing with excellent thermoelectric properties and mechanical robustness.

Mechanical metamaterials made of freestanding quasi-BCC nanolattices of gold and copper with ultra-high energy absorption capacity

Nanolattices exhibit attractive mechanical properties such as high strength, high specific strength, and high energy absorption. However, at present, such materials cannot achieve effective fusion of the above properties and scalable production, which hinders their applications in energy conversion and other fields. Herein, we report gold and copper quasi-body centered cubic (quasi-BCC) nanolattices with the diameter of the nanobeams as small as 34 nm. We show that the compressive yield strengths of quasi-BCC nanolattices even exceed those of their bulk counterparts, despite their relative densities below 0.5. Simultaneously, these quasi-BCC nanolattices exhibit ultrahigh energy absorption capacities, i.e., 100 ± 6 MJ m^-3 for gold quasi-BCC nanolattice and 110 ± 10 MJ m^-3 for copper quasi-BCC nanolattice. Finite element simulations and theoretical calculations reveal that the deformation of quasi-BCC nanolattice is dominated by nanobeam bending. And the anomalous energy absorption capacities substantially stem from the synergy of the naturally high mechanical strength and plasticity of metals, the size reduction-induced mechanical enhancement, and the quasi-BCC nanolattice architecture. Since the sample size can be scaled up to macroscale at high efficiency and affordable cost, the quasi-BCC nanolattices with ultrahigh energy absorption capacity reported in this work may find great potentials in heat transfer, electric conduction, catalysis applications.

Bioinspired Nanonetwork Hydroxyapatite from Block Copolymer Templated Synthesis for Mechanical Metamaterials

Inspired by Mantis shrimp, this work aims to suggest a bottom-up approach for the fabrication of nanonetwork hydroxyapatite (HAp) thin film using self-assembled polystyrene-block-polydimethylsiloxane (PS-b-PDMS) block copolymer (BCP) with a diamond nanostructure as a template for templated sol-gel reaction. By introducing poly(vinylpyrrolidone) (PVP) into precursors of calcium nitrate tetrahydrate and triethyl phosphite, which limits the growth of forming HAp nanoparticles, well-ordered nanonetwork HAp thin film can be fabricated. Based on nanoindentation results, the well-ordered nanonetwork HAp shows high energy dissipation compared to the intrinsic HAp. Moreover, the uniaxial microcompression test for the nanonetwork HAp shows high energy absorption per volume and high compression strength, outperforming many cellular materials due to the topologic effect of the well-ordered network at the nanoscale. This work highlights the potential of exploiting BCP templated synthesis to fabricate ionic solid materials with a well-ordered nanonetwork monolith, giving rise to the brittle-to-ductile transition, and thus appealing mechanical properties with the character of mechanical metamaterials.

Mechanical nanolattices printed using nanocluster-based photoresists

Natural materials exhibit emergent mechanical properties as a result of their nanoarchitected, nanocomposite structures with optimized hierarchy, anisotropy, and nanoporosity. Fabrication of such complex systems is currently challenging because high-quality three-dimensional (3D) nanoprinting is mostly limited to simple, homogeneous materials. We report a strategy for the rapid nanoprinting of complex structural nanocomposites using metal nanoclusters. These ultrasmall, quantum-confined nanoclusters function as highly sensitive two-photon activators and simultaneously serve as precursors for mechanical reinforcements and nanoscale porogens. Nanocomposites with complex 3D architectures are printed, as well as structures with tunable, hierarchical, and anisotropic nanoporosity. Nanocluster-polymer nanolattices exhibit high specific strength, energy absorption, deformability, and recoverability. This framework provides a generalizable, versatile approach for the use of photoactive nanomaterials in additive manufacturing of complex systems with emergent mechanical properties.

Nanoarchitected metal/ceramic interpenetrating phase composites

Architected metals and ceramics with nanoscale cellular designs, e.g., nanolattices, are currently subject of extensive investigation. By harnessing extreme material size effects, nanolattices demonstrated classically inaccessible properties at low density, with exceptional potential for superior lightweight materials. This study expands the concept of nanoarchitecture to dense metal/ceramic composites, presenting co-continuous architectures of three-dimensional printed pyrolytic carbon shell reinforcements and electrodeposited nickel matrices. We demonstrate ductile compressive deformability with elongated ultrahigh strength plateaus, resulting in an extremely high combination of compressive strength and strain energy absorption. Simultaneously, property-to-weight ratios outperform those of lightweight nanolattices. Superior to cellular nanoarchitectures, interpenetrating nanocomposites may combine multiple size-dependent characteristics, whether mechanical or functional, which are radically antagonistic in existing materials. This provides a pathway toward previously unobtainable multifunctionality, extending far beyond lightweight structure applications.

Compressive Property of Additively-Manufactured Micro-Architectures with X-Type Lattice Unit Cell

In this paper, novel micro-architectures with X-type lattice unit cell (namely, face-centered cubic (FCC), and X-type) are constructed and prepared by additive manufacturing technology. The compression behaviors of micro-architectures are explored in detail by experimental measurement and theoretical prediction. It is found that the strength of FCC micro-lattice structure is higher than that of the X-type micro-lattice structure with the same relative density. The X-type micro-lattice structure exhibits a zero Poisson’s ratio during compression deformation. In addition, the compressive strength and energy absorption efficiency of proposed micro-architectures shows a higher advantage over other previously cellular materials in a map for material selection.

The Dynamic Impact Response of 3D-Printed Polymeric Sandwich Structures with Lattice Cores: Numerical and Experimental Investigation

This paper proposes a dynamic drop weight impact simulation to predict the impact response of 3D printed polymeric sandwich structures using an explicit finite element (FE) approach. The lattice cores of sandwich structures were based on two unit cells, a body-centred cubic (BCC) and an edge-centred cubic (ECC). The deformation and the peak acceleration, referred to as the g-max score, were calculated to quantify their shock absorption characteristic. For the FE results verification, a falling mass impact test was conducted. The FE results were in good agreement with experimental measurements. The results suggested that the strut diameter, strut length, number and orientation, and the apparent material stiffness of the lattice cores had a significant effect on their deformation behavior and shock absorption capability. In addition, the BCC lattice core with a thinner strut diameter and low structural height might lead to poor shock absorption capability caused by structure collapse and border effect, which could be improved by increasing its apparent material stiffness. This dynamic drop impact simulation process could be applied across numerous industries such as footwear, sporting goods, personal protective equipment, packaging, or biomechanical implants.

Nanonetwork Thermosets from Templated Polymerization for Enhanced Energy Dissipation

Herein, we aim to develop a facile method for the fabrication of mechanical metamaterials from templated polymerization of thermosets including phenolic and epoxy resins using self-assembled block copolymer, polystyrene-polydimethylsiloxane with tripod network (gyroid), and tetrapod network (diamond) structures, as templates. Nanoindentation studies on the nanonetwork thermosets fabricated reveal enhanced energy dissipation from intrinsic brittle thermosets due to the deliberate structuring; the calculated energy dissipation for gyroid phenolic resins is 0.23 nJ whereas the one with diamond structure gives a value of 0.33 nJ. Consistently, the gyroid-structured epoxy gives a high energy dissipation value of 0.57 nJ, and the one with diamond structure could reach 0.78 nJ. These enhanced properties are attributed to the isotropic periodicity of the nanonetwork texture with plastic deformation, and the higher number of struts in the tetrapod diamond network in contrast to tripod gyroid, as confirmed by the finite element analysis.

Static and Dynamic Responses of Micro-Structured Beams

In this study, we developed a one-dimensional Timoshenko beam model, embedded in a 3D space for static and dynamic analyses of beam-like structures. These are grid cylinders, that is, micro-structured bodies, made of a periodic and specifically designed three-dimensional assembly of beams. Derivation is performed in the framework of the direct 1D approach, while the constitutive law is determined by a homogenization procedure based on an energy equivalence between a cell of the periodic model and a segment of the solid beam. Warping of the cross-section, caused by shear and torsion, is approximatively taken into account by the concept of a shear factor, namely, a corrective factor for the constitutive coefficients of the equivalent beam. The inertial properties of the Timoshenko model are analytically identified under the hypothesis, and the masses are lumped at the joints. Linear static and dynamic responses of some micro-structured beams, taken as case studies, are analyzed, and a comparison between the results given by the Timoshenko model and those obtained by Finite-Element analyses on 3D frames is made. In this framework, the effectiveness of the equivalent model and its limits of applicability are highlighted.

Buckling of Planar Micro-Structured Beams

In this paper, a Timoshenko beam model is formulated for buckling analysis of periodic micro-structured beams, uniformly compressed. These are planar grid beams, whose micro-structure consists of a square lattice of equal fibers, modeled as Timoshenko micro-beams. The equivalent beam model is derived in the framework of a direct one-dimensional approach and its constitutive law, including the effect of prestress of the longitudinal fibers, is deduced through a homogenization approach. Accordingly, micro–macro constitutive relations are obtained through an energy equivalence between a cell of the periodic model and a segment of the equivalent beam. The model also accounts for warping of the micro-structure, via the introduction of elastic and geometric corrective factors of the constitutive coefficients. A survey of the buckling behavior of sample grid beams is presented to validate the effectiveness and limits of the equivalent model. To this purpose, results supplied by the exact analyses of the equivalent beam are compared with those given by finite element models of bi-dimensional frames.

Insights into unit cell size effect on mechanical responses and energy absorption capability of titanium graded porous structures manufactured by laser powder bed fusion

Schwartz diamond graded porous structures (SDGPSs), constructed by a triply-periodic-minimal-surface diamond unit cell topology, were developed with various unit cell sizes and printed by laser powder bed fusion (LPBF) from a commercially pure titanium powder for bone implant applications. The effect of unit cell size on the printability, strut dimensions, stress and strain distributions, mechanical properties and energy absorption capability of SDGPSs was investigated. The results indicate the good printability of SDGPSs via LPBF with multiple unit cell sizes from 3.5 mm to 5.5 mm through the three-dimensional reconstruction from micro-computed tomography. The unit cell size plays a critical role in both strut diameters and specific surface areas of SDGPSs. An increase in the unit cell size leads to a reduction in the experimental Young's modulus from 673.08 MPa to 518.71 MPa and compressive yield strength from 11.43 MPa to 7.73 MPa. The mechanical properties of LPBF-printed SDGPSs are higher than those predicted by the finite element method, which is attributed to the higher volume fractions of the printed SDGPSs than the designed values. Furthermore, a rise in unit cell size leads to the decrease of energy absorption capability from 6.06 MJ/mm³ to 4.32 MJ/mm³ and exhibits little influence on the absorption efficiency. These findings provide a good understanding and guidance to the optimization on the unit cell size of functionally graded porous structures for desirable properties.

Design, Fabrication, and Mechanics of 3D Micro-/Nanolattices

Over the past several decades, lattice materials have been developed and used as engineering materials for lightweight and stiff industrial structures. Recent advances in additive manufacturing techniques have prompted the emergence of architected materials with minimum characteristic sizes ranging from several micrometers to hundreds of nanometers. Taking advantage of the topological design, structural optimization, and size effects of nanomaterials, various 3D micro-/nanolattice materials composed of different materials exhibit combinations of superior mechanical properties, such as low density, high strength (even approaching the theoretical limits), large deformability, good recoverability, and flaw tolerance. As a result, some micro-/nanolattices occupy an unprecedented area in Ashby charts with a combination of different material properties. Here, recent advances in the fabrication and mechanics of micro-/nanolattices are described. First, various design principles and advanced techniques used for the fabrication of micro-/nanolattices are summarized. Then, the mechanical behaviors and properties of micro-/nanolattices are further described, including the compressive Young's modulus, strength, energy absorption, recoverability, and tensile behavior, with an emphasis on mechanistic insights and origins. Finally, the main challenges in the fabrication and mechanics of micro-/nanolattices are addressed and an outlook for further investigations and potential applications of micro-/nanolattices in the future is provided.

Plate-nanolattices at the theoretical limit of stiffness and strength

Though beam-based lattices have dominated mechanical metamaterials for the past two decades, low structural efficiency limits their performance to fractions of the Hashin-Shtrikman and Suquet upper bounds, i.e. the theoretical stiffness and strength limits of any isotropic cellular topology, respectively. While plate-based designs are predicted to reach the upper bounds, experimental verification has remained elusive due to significant manufacturing challenges. Here, we present a new class of nanolattices, constructed from closed-cell plate-architectures. Carbon plate-nanolattices are fabricated via two-photon lithography and pyrolysis and shown to reach the Hashin-Shtrikman and Suquet upper bounds, via in situ mechanical compression, nano-computed tomography and micro-Raman spectroscopy. Demonstrating specific strengths surpassing those of bulk diamond and average performance improvements up to 639% over the best beam-nanolattices, this study provides detailed experimental evidence of plate architectures as a superior mechanical metamaterial topology.

Plate-lattices are predicted to reach the upper bounds of strength and stiffness compared to traditional beam-lattices, but they are difficult to manufacture. Here, the authors use two-photon polymerization 3D-printing and pyrolysis to make carbon plate-nanolattices which reach those theoretical bounds, making them up to 639% stronger than beam-nanolattices.

Tunable Energy Absorption Characteristics of Architected Honeycombs Enabled via Additive Manufacturing

Tailoring of material architectures in three-dimensions enabled by additive manufacturing (AM) offers the potential to realize bulk materials with unprecedented properties optimized for location-specific structural and/or functional requirements. Here we report tunable energy absorption characteristics of architected honeycombs enabled via material jetting AM. We realize spatially tailored 3D printed honeycombs (guided by FE studies) by varying the cell wall thickness gradient and evaluate experimentally and numerically the energy absorption characteristics. The measured response of architected honeycombs characterized by local buckling (wrinkling) and progressive failure reveals over 110% increase in specific energy absorption (SEA) with a concomitant energy absorption efficiency of 65%. Design maps are presented that demarcate the regime over which geometric tailoring mitigates deleterious global buckling and collapse. Our analysis indicates that an energy absorption efficiency as high as 90% can be achieved for architected honeycombs, whereas the efficiency of competing microarchitected metamaterials rarely exceeds 50%. The tailoring strategy introduced here is easily realizable in a broad array of AM techniques, making it a viable candidate for developing practical mechanical metamaterials.

Ultrahigh Energy Absorption Multifunctional Spinodal Nanoarchitectures

Nanolattices are promoted as next-generation multifunctional high-performance materials, but their mechanical response is limited to extreme strength yet brittleness, or extreme deformability but low strength and stiffness. Ideal impact protection systems require high-stress plateaus over long deformation ranges to maximize energy absorption. Here, glassy carbon nanospinodals, i.e., nanoarchitectures with spinodal shell topology, combining ultrahigh energy absorption and exceptional strength and stiffness at low weight are presented. Noncatastrophic deformation up to 80% strain, and energy absorption up to one order of magnitude higher than for other nano-, micro-, macro-architectures and solids, and state-of-the-art impact protection structures are shown. At the same time, the strength and stiffness are on par with the most advanced yet brittle nanolattices, demonstrating true multifunctionality. Finite element simulations show that optimized shell thickness-to-curvature-radius ratios suppress catastrophic failure by impeding propagation of dangerously oriented cracks. In contrast to most micro- and nano-architected materials, spinodal architectures may be easily manufacturable on an industrial scale, and may become the next generation of superior cellular materials for structural applications.

Three-Dimensional High-Entropy Alloy-Polymer Composite Nanolattices That Overcome the Strength-Recoverability Trade-off

Mechanical metamaterials with three-dimensional micro- and nanoarchitectures exhibit unique mechanical properties, such as high specific modulus, specific strength, and energy absorption. However, a conflict exists between strength and recoverability in nearly all the mechanical metamaterials reported recently, in particular the architected micro/nanolattices, which restricts the applications of these materials in energy storage/absorption and mechanical actuation. Here, we demonstrated the fabrication of three-dimensional architected composite nanolattices that overcome the strength-recoverability trade-off. The nanolattices under study are made up of a high-entropy alloy-coated (14.2-126.1 nm in thickness) polymer strut (approximately 260 nm in the characteristic size) fabricated via two-photon lithography and magnetron sputtering deposition. In situ uniaxial compression inside a scanning electron microscope showed that these composite nanolattices exhibit a high specific strength of 0.027 MPa/kg m³, an ultrahigh energy absorption per unit volume of 4.0 MJ/m³, and nearly complete recovery after compression under strains exceeding 50%, thus overcoming the traditional strength-recoverability trade-off. During multiple compression cycles, the composite nanolattices exhibit a high energy loss coefficient (converged value after multiple cycles) of 0.5-0.6 at a compressive strain beyond 50%, surpassing the coefficients of all the micro/nanolattices fabricated recently. Our experiments also revealed that, for a given unit cell size, the composite nanolattices coated with a high entropy alloy with thickness in the range of 14-50 nm have the optimal specific modulus, specific strength, and energy absorption per unit volume, which is related to a transition of the dominant deformation mechanism from local buckling to brittle fracture of the struts.

Mechanical Enhancement of Core-Shell Microlattices through High-Entropy Alloy Coating

Mechanical metamaterials such as microlattices are an emerging kind of new materials that utilize the combination of structural enhancement effect by geometrical modification and the intrinsic properties of its material constituents. Prior studies have reported the mechanical properties of ceramic or metal-coated composite lattices. However, the scalable synthesis and characterization of high-entropy alloy (HEA) as thin film coating for such cellular materials have not been studied previously. In this work, stereolithography was combined with Radio Frequency (RF) magnetron sputtering to conformally deposit a thin layer (~800 nm) of CrMnFeCoNi HEA film onto a polymer template to produce HEA-coated three-dimensional (3D) core-shell microlattice structures for the first time. The presented polymer/HEA hybrid microlattice exhibits high specific compressive strength (~0.018 MPa kg^-1 m³) at a density well below 1000 kg m^-3, significantly enhanced stiffness (>5 times), and superior elastic recoverability compared to its polymer counterpart due to its composite nature. The findings imply that this highly scalable and effective route to synthesizing HEA-coated microlattices have the potential to produce novel metamaterials with desirable properties to cater specialized engineering applications.

Development of ultralight, super-elastic, hierarchical metallic meta-structures with i3DP technology

Lightweight and mechanically robust materials show promising applications in thermal insulation, energy absorption, and battery catalyst supports. This study demonstrates an effective method for creation of ultralight metallic structures based on initiator-integrated 3D printing technology (i3DP), which provides a possible platform to design the materials with the best geometric parameters and desired mechanical performance. In this study, ultralight Ni foams with 3D interconnected hollow tubes were fabricated, consisting of hierarchical features spanning three scale orders ranging from submicron to centimeter. The resultant materials can achieve an ultralight density of as low as 5.1 mg cm^-3 and nearly recover after significant compression up to 50%. Due to a high compression ratio, the hierarchical structure exhibits superior properties in terms of energy absorption and mechanical efficiency. The relationship of structural parameters and mechanical response was established. The ability of achieving ultralight density <10 mg cm^-3 and the stable [Formula: see text] scaling through all range of relative density, indicates an advantage over the previous stochastic metal foams. Overall, this initiator-integrated 3D printing approach provides metallic structures with substantial benefits from the hierarchical design and fabrication flexibility to ultralight applications.

Nanolattices: An Emerging Class of Mechanical Metamaterials

In 1903, Alexander Graham Bell developed a design principle to generate lightweight, mechanically robust lattice structures based on triangular cells; this has since found broad application in lightweight design. Over one hundred years later, the same principle is being used in the fabrication of nanolattice materials, namely lattice structures composed of nanoscale constituents. Taking advantage of the size-dependent properties typical of nanoparticles, nanowires, and thin films, nanolattices redefine the limits of the accessible material-property space throughout different disciplines. Herein, the exceptional mechanical performance of nanolattices, including their ultrahigh strength, damage tolerance, and stiffness, are reviewed, and their potential for multifunctional applications beyond mechanics is examined. The efficient integration of architecture and size-affected properties is key to further develop nanolattices. The introduction of a hierarchical architecture is an effective tool in enhancing mechanical properties, and the eventual goal of nanolattice design may be to replicate the intricate hierarchies and functionalities observed in biological materials. Additive manufacturing and self-assembly techniques enable lattice design at the nanoscale; the scaling-up of nanolattice fabrication is currently the major challenge to their widespread use in technological applications.