The mechanical properties of cellular solids

Synthesis of bio-polyol-functionalized nanocrystalline celluloses as reactive/reinforcing components in bio-based polyurethane foams by homogeneous environment modification

Nanocrystalline Cellulose (NCC or CNC) is widely used as a filler in polymer composites due to its high specific strength, tensile modulus, aspect ratio, and sustainability. However, CNC hydrophilicity complicates its dispersion in hydrophobic polymeric matrices giving rise to aggregate structures and thus compromising its reinforcing action. CNC functionalization in a homogeneous environment, through silanization with trichloro(butyl)silane as a coupling agent and subsequent grafting with bio-based polyols, is herein investigated aiming to enhance CNC dispersibility improving the filler-matrix interaction between the hydrophobic PU and hydrophilic CNC. The modified CNCs (m_Ci) have been studied by XRD, SEM, and TGA analyses. The TGA results show that the amount of grafted polyol is strongly influenced by both its molar mass and OH number and the maximum amount of grafted polyol reaches up to 0.32 mmol per grams of functionalized CNC, within the explored conditions. The effect of different concentrations (1-3 wt%) of m_Ci on the physical, morphological, and mechanical properties of the resulting bio-based composite polyurethane foams is evaluated. Composite PU foams present compressive modulus up to 4.81 MPa and strength up to 255 kPa more than five times higher than those reinforced with unmodified CNC or with modified CNC in heterogeneous chemical environment. The improvement of mechanical properties of the examined PU foams, as a consequence of the incorporation of bio-polyols modified CNCs where polyol's OH groups interact with polyurethane precursors, could further broaden the use of these materials in building applications.

Nature's Load-Bearing Design Principles and Their Application in Engineering: A Review

Biological structures optimized through natural selection provide valuable insights for engineering load-bearing components. This paper reviews six key strategies evolved in nature for efficient mechanical load handling: hierarchically structured composites, cellular structures, functional gradients, hard shell-soft core architectures, form follows function, and robust geometric shapes. The paper also discusses recent research that applies these strategies to engineering design, demonstrating their effectiveness in advancing technical solutions. The challenges of translating nature's designs into engineering applications are addressed, with a focus on how advancements in computational methods, particularly artificial intelligence, are accelerating this process. The need for further development in innovative material characterization techniques, efficient modeling approaches for heterogeneous media, multi-criteria structural optimization methods, and advanced manufacturing techniques capable of achieving enhanced control across multiple scales is underscored. By highlighting nature's holistic approach to designing functional components, this paper advocates for adopting a similarly comprehensive methodology in engineering practices to shape the next generation of load-bearing technical components.

Additive Manufacturing of Poly(phenylene Sulfide) Aerogels via Simultaneous Material Extrusion and Thermally Induced Phase Separation

Additive manufacturing (AM) of aerogels increases the achievable geometric complexity, and affords fabrication of hierarchically porous structures. In this work, a custom heated material extrusion (MEX) device prints aerogels of poly(phenylene sulfide) (PPS), an engineering thermoplastic, via in situ thermally induced phase separation (TIPS). First, pre-prepared solid gel inks are dissolved at high temperatures in the heated extruder barrel to form a homogeneous polymer solution. Solutions are then extruded onto a room-temperature substrate, where printed roads maintain their bead shape and rapidly solidify via TIPS, thus enabling layer-wise MEX AM. Printed gels are converted to aerogels via postprocessing solvent exchange and freeze-drying. This work explores the effect of ink composition on printed aerogel morphology and thermomechanical properties. Scanning electron microscopy micrographs reveal complex hierarchical microstructures that are compositionally dependent. Printed aerogels demonstrate tailorable porosities (50.0-74.8%) and densities (0.345-0.684 g cm-3), which align well with cast aerogel analogs. Differential scanning calorimetry thermograms indicate printed aerogels are highly crystalline (≈43%), suggesting that printing does not inhibit the solidification process occurring during TIPS (polymer crystallization). Uniaxial compression testing reveals that compositionally dependent microstructure governs aerogel mechanical behavior, with compressive moduli ranging from 33.0 to 106.5 MPa.

Imprinting reversible deformations on a compressed soft rod network

We present emergent behaviour of storing mechanical deformation in compressed soft cellular materials (a network of soft polymeric rods). Under an applied compressive strain field, the soft cellular material transits from an elastic regime to a 'pseudo-plastic' regime (not to be confused with pseudoplasticity in fluids). In the elastic phase, it is capable of forgetting (or relaxing) any applied indentation once the applied indentation is removed. This relaxation will be determined by the visco-elasticity and internal relaxation timescales in polymeric hyperelastic cellular materials. In the pseudo-plastic phase, however, the material is capable of storing local indentation (or deformation) indefinitely. This deformation can be erased via removal of the external strain field and is therefore reversible. We characterise this behaviour experimentally and present a simple model that makes use of friction for understanding this behavior.

Gastroretentive fibrous dosage forms for prolonged delivery of sparingly-soluble tyrosine kinase inhibitors. Part 2: Experimental validation of the models of expansion, post-expansion mechanical strength, and drug release

In Part 1, we have introduced expandable gastroretentive fibrous dosage forms for prolonged delivery of sparingly-soluble tyrosine kinase inhibitors. The expansion rate, post-expansion mechanical strength, and drug release rate were modeled for a dosage form containing 200 mg nilotinib. In the present part, the dosage form was prepared and tested in vitro to validate the models. Upon immersing in a dissolution fluid, the fibrous dosage form expanded at a constant rate to a normalized radial expansion of 0.5 by 4 h, and then formed an expanded viscoelastic mass of high strength. The drug was released at a constant rate over a day. For comparison, a particle-filled gelatin capsule with the same amount of nilotinib disintegrated almost immediately, and released eighty percent of the drug content in just 10 min. The experimental data validate the theoretical models of Part 1 reasonably.

Gastroretentive fibrous dosage forms for prolonged delivery of sparingly-soluble tyrosine kinase inhibitors. Part 1: Dosage form design, and models of expansion, post-expansion mechanical strength, and drug release

At present, the efficacy and safety of many sparingly-soluble tyrosine kinase inhibitors (TKIs) delivered by the prevalent oral dosage forms are compromised by excessive fluctuations in the drug concentration in blood. To mitigate this limitation, in this four-part study gastroretentive fibrous dosage forms that deliver drug into the gastric fluid (and into the blood) at a controlled rate for prolonged time are presented. The dosage form comprises a cross-ply structure of expandable, water-absorbing, high-molecular-weight hydroxypropyl methylcellulose (HPMC)-based fibers coated with a strengthening, enteric excipient. The intervening spaces between the coated fibers are solid annuli of drug particles, and low-molecular-weight HPMC and enteric excipients. The central regions of the annuli are open channels. In this part, models are developed for dosage form expansion, post-expansion mechanical strength, and drug release. The models suggest that upon immersing in a dissolution fluid, the fluid percolates the open channels, diffuses into the annuli and the coated fibers, and the dosage form expands. The expansion rate is inversely proportional, and the post-expansion mechanical strength proportional to the thickness of the strengthening coating. Drug particles are released from the annuli as the surrounding excipient dissolves. The drug release rate is proportional to the concentration of low-molecular-weight HPMC at the annulus/dissolution fluid interface. The dosage forms can be readily designed for expansion in a few hours, formation of a high-strength viscoelastic mass, and drug release at a constant rate over a day.

Gastroretentive fibrous dosage forms for prolonged delivery of sparingly-soluble tyrosine kinase inhibitors. Part 3: Theoretical models of drug concentration in blood

In this part, drug concentration in blood after ingesting slow-release gastroretentive fibrous dosage forms and immediate-release particulate forms is modeled. The tyrosine kinase inhibitor nilotinib, which is slightly soluble in low-pH gastric fluid but practically insoluble in pH-neutral intestinal fluid is used as drug. The models suggest that upon ingestion, the fibrous dosage form expands, is retained in the stomach for prolonged time, and releases drug into the gastric fluid at a constant rate. The released drug molecules flow into the duodenum with the gastric fluid, and are absorbed by the blood. The drug is eliminated from the blood by the liver at a rate proportional to its concentration. Eventually, the elimination and absorption rates will be equal, and the drug concentration in blood plateaus out. After the gastric residence time drug absorption stops, and the drug concentration in blood drops to zero. By contrast, after administering an immediate-release particulate dosage form the drug particles are swept out of the stomach rapidly, and drug absorption stops much earlier. The drug concentration in blood rises and falls without attaining steady state. The gastroretentive fibrous dosage forms enable a constant drug concentration in blood for drugs that are insoluble in intestinal fluids.

De Novo Atomistic Discovery of Disordered Mechanical Metamaterials by Machine Learning

Architected materials design across orders of magnitude length scale intrigues exceptional mechanical responses nonexistent in their natural bulk state. However, the so-termed mechanical metamaterials, when scaling bottom down to the atomistic or microparticle level, remain largely unexplored and conventionally fall out of their coarse-resolution, ordered-pattern design space. Here, combining high-throughput molecular dynamics (MD) simulations and machine learning (ML) strategies, some intriguing atomistic families of disordered mechanical metamaterials are discovered, as fabricated by melt quenching and exemplified herein by lightweight-yet-stiff cellular materials featuring a theoretical limit of linear stiffness-density scaling, whose structural disorder-rather than order-is key to reduce the scaling exponent and is simply controlled by the bonding interactions and their directionality that enable flexible tunability experimentally. Importantly, a systematic navigation in the forcefield landscape reveals that, in-between directional and non-directional bonding such as covalent and ionic bonds, modest bond directionality is most likely to promotes disordered packing of polyhedral, stretching-dominated structures responsible for the formation of metamaterials. This work pioneers a bottom-down atomistic scheme to design mechanical metamaterials formatted disorderly, unlocking a largely untapped field in leveraging structural disorder in devising metamaterials atomistically and, potentially, generic to conventional upscaled designs.

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.

Directional actuation and phase transition-like behavior in anisotropic networks of responsive microfibers

Two-dimensional shape-morphing networks are common in biological systems and have garnered attention due to their nontrivial physical properties that emanate from their cellular nature. Here, we present the fabrication and characterization of anisotropic shape-morphing networks composed of thermoresponsive polymeric microfibers. By strategically positioning fibers with varying responses, we construct networks that exhibit directional actuation. The individual segments within the network display either a linear extension or buckling upon swelling, depending on their radius and length, and the transition between these morphing behaviors resembles Landau's second-order phase transition. The microscale variations in morphing behaviors are translated into observable macroscopic effects, wherein regions undergoing linear expansion retain their shape upon swelling, whereas buckled regions demonstrate negative compressibility and shrink. Manipulating the macroscale morphing by adjusting the properties of the fibrous microsegments offers a means to modulate and program morphing with mesoscale precision and unlocks novel opportunities for developing programmable microscale soft robotics and actuators.

Collagen Networks under Indentation and Compression Behave Like Cellular Solids

Simple synthetic and natural hydrogels can be formulated to have elastic moduli that match biological tissues, leading to their widespread application as model systems for tissue engineering, medical device development, and drug delivery vehicles. However, two different hydrogels having the same elastic modulus but differing in microstructure or nanostructure can exhibit drastically different mechanical responses, including their poroelasticity, lubricity, and load bearing capabilities. Here, we investigate the mechanical response of collagen-1 networks to local and bulk compressive loads. We compare these results to the behavior of polyacrylamide, a fundamentally different class of hydrogel network consisting of flexible polymer chains. We find that the high bending rigidity of collagen fibers, which suppresses entropic bending fluctuations and osmotic pressure, facilitates the bulk compression of collagen networks under infinitesimal applied stress. These results are fundamentally different from the behavior of flexible polymer networks in which the entropic thermal fluctuations of the polymer chains result in an osmotic pressure that must first be overcome before bulk compression can occur. Furthermore, we observe minimal transverse strain during the axial loading of collagen networks, a behavior reminiscent of open-celled cellular solids. Inspired by these results, we applied mechanical models of cellular solids to predict the elastic moduli of the collagen networks and found agreement with the moduli values measured through contact indentation. Collectively, these results suggest that unlike flexible polymer networks that are often considered incompressible, collagen hydrogels behave like rigid porous solids that volumetrically compress and expel water rather than spreading laterally under applied normal loads.

Ultralight, strong, and self-reprogrammable mechanical metamaterials

Versatile programmable materials have long been envisioned that can reconfigure themselves to adapt to changing use cases in adaptive infrastructure, space exploration, disaster response, and more. We introduce a robotic structural system as an implementation of programmable matter, with mechanical performance and scale on par with conventional high-performance materials and truss systems. Fiber-reinforced composite truss-like building blocks form strong, stiff, and lightweight lattice structures as mechanical metamaterials. Two types of mobile robots operate over the exterior surface and through the interior of the system, performing transport, placement, and reversible fastening using the intrinsic lattice periodicity for indexing and metrology. Leveraging programmable matter algorithms to achieve scalability in size and complexity, this system design enables robust collective automated assembly and reconfiguration of large structures with simple robots. We describe the system design and experimental results from a 256-unit cell assembly demonstration and lattice mechanical testing, as well as a demonstration of disassembly and reconfiguration. The assembled structural lattice material exhibits ultralight mass density (0.0103 grams per cubic centimeter) with high strength and stiffness for its weight ( 11.38 kilopascals and 1.1129 megapascals, respectively), a material performance realm appropriate for applications like space structures. With simple robots and structure, high mass-specific structural performance, and competitive throughput, this system demonstrates the potential for self-reconfiguring autonomous metamaterials for diverse applications.

Material Behavior of PIR Rigid Foam in Sandwich Panels: Studies beyond Construction Industry Standard

A deep understanding of the material parameters and the behavior of sandwich panels, which are used in the construction industry as roof and façade cladding, is important for the design of these construction components. Due to the constant changes in the polyurethane (PU) foams used as a core material, the experimental database for the current foams is small. Nowadays, there is an increasing number of failures of façade and roof panels after installation. This article presents a variety of experimental investigations on sandwich panels from two manufacturers with a core of polyisocyanurate (PIR) rigid foam (density: 40 kg/m3). As part of this study, compression, tension, shear, and bending tests were performed in several spatial directions and over the range required by the standard. The results of the tests showed the orthotropy of the core material and the dependence of the material on the direction and type of load. The stress-strain curves showed linear and non-linear areas. Using the data from this experimental study, a numerical model was implemented which utilized the Hill yield criterion to represent the orthotropy of the core material. The present investigation suggests that the classical von Mises failure criterion, used in many studies, is not suitable for the foam system applied in these sandwich panels. Instead, the Tsai-Wu criterion is more appropriate for defining the failure stresses.

Strain-based method for fatigue failure prediction of additively manufactured lattice structures

Lattice structures find application in numerous technological domains, including aerospace and automotive industries for structural components, biomedical sector implants, and heat exchangers. In many instances, especially those pertaining to structural applications, fatigue resistance stands as a critical and stringent requirement. The objective of this paper is to advance the analysis of fatigue failure in additively manufactured lattice structures by introducing a predictive fatigue failure model based on the finite element (FE) method and experimentally validating the results. The model utilizes linear homogenization to reduce computational effort in FE simulations. By employing a strain-based parameter, the most critical lattice cell is identified, enabling the prediction of fatigue crack nucleation locations. The Crossland multiaxial fatigue failure criterion is employed to assess the equivalent stress, furnishing the fatigue limit threshold essential for predicting component failure. Inconel 625 specimens are manufactured via the laser-based powder bed fusion of metals additive manufacturing process. In order to validate the model, cantilevers comprising octa-truss lattice cells in both uniform and graded configurations undergo experimental testing subjected to bending loads within the high cycle fatigue regime. The proposed methodology effectively forecasts the location of failure in seventeen out of eighteen samples, establishing itself as a valuable tool for lattice fatigue analysis. Failure consistently manifests in sections of uniform and graded lattice structures characterized by the maximum strain tensor norm. The estimated maximum force required to prevent fatigue failure in the samples is 20 N, based on the computed Crossland equivalent stress.

Betholletia excelsa Fruit: Unveiling Toughening Mechanisms and Biomimetic Potential for Advanced Materials

Dry fruits and nutshells are biological capsules of outstanding toughness and strength with biomimetic potential to boost fiber-reinforced composites and protective structures. The strategies behind the Betholletia excelsa fruit mechanical performance were investigated with C-ring and compression tests. This last test was monitored with shearography and simulated with a finite element model. Microtomography and digital and scanning electron microscopy evaluated crack development. The fruit geometry, the preferential orientation of fibers involved in foam-like sclereid cells, promoted anisotropic properties but efficient energy dissipating mechanisms in different directions. For instance, the mesocarp cut parallel to its latitudinal section sustained higher forces (26.0 ± 2.8 kN) and showed higher deformation and slower crack propagation. The main toughening mechanisms are fiber deflection and fiber bridging and pullout, observed when fiber bundles are orthogonal to the crack path. Additionally, the debonding of fiber bundles oriented parallel to the crack path and intercellular cracks through sclereid and fiber cells created a tortuous path.

All-Nanochitin-Derived, Super-Compressible, Elastic, and Robust Carbon Honeycombs and Their Pressure-Sensing Properties over an Ultrawide Temperature Range

Elastic carbon aerogels show great potential for various applications but are often hindered by structure-derived fatigue failure, weak elasticity with low compressibility, and low stress and height retention. Herein, we demonstrate a super-elastic and fatigue-resistant nanochitin-derived carbon honeycomb with honeycomb-like anisotropic microstructures and carbon-based molecular structures, which was tailored by optimizing the nanochitin concentrations and carbonization temperatures. The carbon honeycomb fabricated at a nanochitin concentration of 1.0 wt % and a carbonization temperature of 900 °C demonstrated anisotropic honeycomb channels, nanofibrous network channel walls with few cracks, and weak interactions between the carbonized nanochitin, which afforded high compressibility with up to 90% strain and complete recovery. In particular, the carbon honeycomb provided good fatigue resistance with high stress and height retentions of 87 and 94%, respectively, after more than 10,000 compression cycles at 90% strain. Moreover, the tailored anisotropic honeycomb channels and molecular structures endowed the carbon honeycomb with elasticity even under severe conditions, such as exposure to flame (approximately 1000 °C) and liquid nitrogen (approximately -196 °C). Owing to these properties, the nanochitin-derived carbon honeycomb could act as a high-sensitivity pressure sensor for a wide working pressure range of 0-185.5 kPa and ultrawide temperature range of -196-600 °C. This study can provide a promising route to develop all-biomass-derived, super-elastic, and fatigue-resistant carbon materials for pressure sensing under harsh conditions and for versatile electronic applications.

Jackfruit: Composition, structure, and progressive collapsibility in the largest fruit on the Earth for impact resistance

The jackfruit is the largest fruit on the Earth, reaching upwards of 35 kg and falling from heights of 25 m. To survive such high energy impacts, it has evolved a unique layered configuration with a thorny exterior and porous tubular underlayer. During compression, these layers exhibit a progressive collapse mechanism where the tubules are first to deform, followed by the thorny exterior, and finally the mesocarp layer in between. The thorns are composed of lignified bundles which run longitudinally from the base of the thorn to the tip and are embedded in softer parenchymal cells, forming a fiber reinforced composite. The mesocarp contains more lignin than any of the other layers while the core appears to contain more pectin giving rise to variations in compressive and viscoelastic properties between the layers. The surface thorns provide a compelling impact-resistant feature for bioinspiration, with a cellular structure that can withstand large deformation without failing and wavy surface features which densify during compression without fracturing. Even the conical shape of the thorns is valuable, presenting a gradually increasing surface area during axial collapse. A simplified model of this mechanism is put forward to describe the force response of these features. The thorns also distribute damage laterally during impact and deflect cracks along their interstitial valleys. These phenomena were observed in 3D printed, jackfruit-inspired designs which performed markedly better than control prints with the same mass. STATEMENT OF SIGNIFICANCE: Many biological materials have evolved remarkable structures that enhance their mechanical performance and serve as sources of inspiration for engineers. Plants are often overlooked in this regard yet certain botanical components, like nuts and fruit, have shown incredible potential as blueprints for improved impact resistant designs. The jackfruit is the largest fruit on Earth and generates significant falling impact energies. Here, we explore the jackfruit's structure and its mechanical capabilities for the first time. The progressive failure imparted by its multilayered design and the unique collapse mode of the surface thorns are identified as key mechanisms for improving the fruit's impact resistance. 3D printing is used to show that these structure-property benefits can be successfully transferred to engineering materials.

The effect of a semi-permeable, strengthening fiber coating on the expansion, mechanical properties, and residence time of gastroretentive fibrous dosage forms

Recently, we have shown in dogs that the gastric residence time of expandable fibrous dosage forms can be prolonged by coating the fibers with a semi-permeable, strengthening coating. In this work on pigs, the effect of the volume fraction of the coating, φc, on the expansion, mechanical strength, and gastric residence time is investigated. Three methacrylic acid-ethyl acrylate-coated fibrous dosage forms with φc = 0.025, 0.041, and 0.068 were prepared and tested. Upon administering to a pig, the dosage forms expanded to a normalized radial expansion of 0.5-0.6 in 5, 8, and 10 h, respectively. The expanded dosage forms resided in the stomach and fragmented after 11, 25, and 31 h. The fragments then passed into the intestines and dissolved in 2-3 h. Models suggest that upon contact with gastric fluid, a hydrostatic pressure develops in the fibers due to the inward diffusion of water. The hydrostatic pressure in turn induces a tensile stress in the coating and the dosage form expands. The tensile stress and the expansion rate are inversely proportional to φc. The expanded dosage form eventually fractures due to the loads applied by the contracting stomach walls. The post-expansion mechanical strength and the time to fracture increase steeply with φc. The models predict the experimental results reasonably well. Thus, by increasing φc, dosage form fracture is delayed and the gastric residence time prolonged.

Energy-Reduced Fabrication of Light-Frame Ceramic Honeycombs by Replication of Additive Manufactured Templates

Ceramic components require very high energy consumption due to synthesis, shaping, and thermal treatment. However, this study suggests that combining the sol-gel process, replica technology, and stereolithography has the potential to produce highly complex geometries with energy savings in each process step. We fabricated light-frame honeycombs of Al₂O₃, Ba_0.85Ca_0.15Zr_0.1Ti_0.9O₃ (BCZT), and BaTiO₃ (BT) using 3D-printed templates with varying structural angles between -30° and 30° and investigated their mechanical and piezoelectric properties. The Al₂O₃ honeycombs showed a maximum strength of approximately 6 MPa, while the BCZT and BaTiO₃ honeycombs achieved a d₃₃ above 180 pC/N. Additionally, the BCZT powder was prepared via a sol-gel process, and the impact of the calcination temperature on phase purity was analyzed. The results suggest that there is a large energy-saving potential for the synthesis of BCZT powder. Overall, this study provides valuable insights into the fabrication of complex ceramic structures with improved energy efficiency and enhancement of performance.

Deep Learning Accelerated Design of Mechanically Efficient Architected Materials

Lattice structures are known to have high performance-to-weight ratios because of their highly efficient material distribution in a given volume. However, their inherently large void fraction leads to low mechanical properties compared to the base material, high anisotropy, and brittleness. Most works to date have focused on modifying the spatial arrangement of beam elements to overcome these limitations, but only simple beam geometries are adopted due to the infinitely large design space associated with probing and varying beam shapes. Herein, we present an approach to enhance the elastic modulus, strength, and toughness of lattice structures with minimal tradeoffs by optimizing the shape of beam elements for a suite of lattice structures. A generative deep learning-based approach is employed, which leverages the fast inference of neural networks to accelerate the optimization process. Our optimized lattice structures possess superior stiffness (+59%), strength (+49%), toughness (+106%), and isotropy (+645%) compared to benchmark lattices consisting of cylindrical beams. We fabricate our lattice designs using additive manufacturing to validate the optimization approach; experimental and simulation results show good agreement. Remarkable improvement in mechanical properties is shown to be the effect of distributed stress fields and deformation modes subject to beam shape and lattice type.

Toughness Amplification via Controlled Nanostructure in Lightweight Nano-Bouligand Materials

The enhanced properties of nanomaterials make them attractive for advanced high-performance materials, but their role in promoting toughness has been unclear. Fabrication challenges often prevent the proper organization of nanomaterial constituents, and inadequate testing methods have led to a poor knowledge of toughness at small scales. In this work, the individual roles of nanomaterials and nanoarchitecture on toughness are quantified by creating lightweight materials made from helicoidal polymeric nanofibers (nano-Bouligand). Unidirectional ( θ $\theta $  = 0°) and nano-Bouligand beams ( θ $\theta $  = 2°-90°) are fabricated using two-photon lithography and are designed in a micro-single edge notch bend (µ-SENB) configuration with relative densities ρ ¯ $\overline \rho $ between 48% and 81%. Experiments demonstrate two unique toughening mechanisms. First, size-enhanced ductility of nanoconfined polymer fibers increases specific fracture energy by 70% in the 0° unidirectional beams. Second, nanoscale stiffness heterogeneity created via inter-layer fiber twisting impedes crack growth and improves absolute fracture energy dissipation by 48% in high-density nano-Bouligand materials. This demonstration of size-enhanced ductility and nanoscale heterogeneity as coexisting toughening mechanisms reveals the capacity for nanoengineered materials to greatly improve mechanical resilience in a new generation of advanced materials.

Influences of Flood Conditions on Dynamic Characteristics of Novel 3D-Printed Porous Bridge Bearings

As the key safety-critical component of a bridge support system, bridge bearings are extensively used to accommodate, balance, and transfer differential displacements and loads between the superstructure and substructure of a bridge during operations. Several studies have been conducted to obtain dynamic modal parameters of traditional bridge bearings only in perfectly dry environments. However, in extreme weather conditions (e.g., heavy rain, flash floods, etc.), water can ingress and change the bearings' properties. In this study, novel 3D-printed porous bridge bearings (3DPPBBs) have been fabricated by Fused Deposition Modeling (FDM) with thermoplastic polyurethane (TPU) filaments. This study is the first to determine the influences of flood conditions on their dynamic properties, which has never been done before. An idealised single degree of freedom (ISDOF) for these novel bearings is considered for the non-destructive field-testing technique of the critical bridge component. A series of experimental tests have been performed under several conditions of flooding levels. The new results unprecedentedly indicate that relatively higher dynamic damping ratios can be found with the increasing flood levels. In contrast, the natural frequencies and dynamic stiffness decrease with the same conditions. Novel insights are essential for bridge engineers to assess and monitor bridge vibrations exposed to extreme weather conditions.

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.

Directing the pore size of rigid polyurethane foam via controlled air entrainment

The interest in polyurethane rigid (PUR) foams as potent thermally insulating materials for a wide range of applications continues to grow as the minimization of CO2 emissions has become a global issue. Controlling the thermal insulation efficiency of PUR foams starts with the control of their morphology. Although the presence of micrometric air bubbles originating from air entrainment during the blending of the PU reactive mixture has been shown to influence the final PUR foam morphology, detailed experimental investigations on how exactly they affect the final PUR foam pore size are still lacking. To fill this gap, we use a double-syringe mixing device, which allows to control the number of air bubbles generated during a first air entrainment step, before using the same device to blend the reactive components in a sealed environment, avoiding further air entrainment. Keeping all experimental parameters constant except for the air bubble density in the reactive mixture, we can correlate changes of the final PUR foam morphology with the variation of the air bubble density in the initially liquid reactive mixture. Our results confirm recent findings which suggest the presence of two different regimes of bubble nucleation and growth depending on the presence or absence of dispersed air bubbles in the liquid reactive mixture. Our study pushes those insights further by demonstrating an inverse relation between the air bubble density in the liquid reactive mixture and the final pore volume of the PUR foam. For example, at constant chemical formulation and blending conditions, we could vary the final pore size between 400–1600 μm simply by controlling the amount of pre-dispersed air bubbles within the system. We are confident that the presented approach may not only provide a valuable model experiment to scan formulations in R&D laboratories, but it may also provide suggestions for the optimization of industrial processes.

Effect of Different Methods to Synthesize Polyol-Grafted-Cellulose Nanocrystals as Inter-Active Filler in Bio-Based Polyurethane Foams

Currently, the scientific community has spent a lot of effort in developing "green" and environmentally friendly processes and products, due the contemporary problems connected to pollution and climate change. Cellulose nanocrystals (CNCs) are at the forefront of current research due to their multifunctional characteristics of biocompatibility, high mechanical properties, specific surface area, tunable surface chemistry and renewability. However, despite these many advantages, their inherent hydrophilicity poses a substantial challenge for the application of CNCs as a reinforcing filler in polymers, as it complicates their dispersion in hydrophobic polymeric matrices, such as polyurethane foams, often resulting in aggregate structures that compromise their properties. The manipulation and fine-tuning of the interfacial properties of CNCs is a crucial step to exploit their full potential in the development of new materials. In this respect, starting from an aqueous dispersion of CNCs, two different strategies were used to properly functionalize fillers: (i) freeze drying, solubilization in DMA/LiCl media and subsequent grafting with bio-based polyols; (ii) solvent exchange and subsequent grafting with bio-based polyols. The influence of the two functionalization methods on the chemical and thermal properties of CNCs was examined. In both cases, the role of the two bio-based polyols on filler functionalization was elucidated. Afterwards, the functionalized CNCs were used at 5 wt% to produce bio-based composite polyurethane foams and their effect on the morphological, thermal and mechanical properties was examined. It was found that CNCs modified through freeze drying, solubilization and bio-polyols grafting exhibited remarkably higher thermal stability (i.e., degradation stages > 100 °C) with respect to the unmodified freeze dried-CNCs. In addition, the use of the two grafting bio-polyols influenced the functionalization process, corresponding to different amount of grafted-silane-polyol and leading to different chemico-physical characteristics of the obtained CNCs. This was translated to higher thermal stability as well as improved functional and mechanical performances of the produced bio-based composite PUR foams with respect of the unmodified CNCs-composite ones (the best case attained compressive strength values three times more). Solvent exchange route slightly improved the thermal stability of the obtained CNCs; however; the so-obtained CNCs could not be properly dispersed within the polyurethane matrix, due to filler aggregation.

Mechanical Properties of AISI 316L Lattice Structures via Laser Powder Bed Fusion as a Function of Unit Cell Features

The growth of additive manufacturing processes has enabled the production of complex and smart structures. These fabrication techniques have led research efforts to focus on the application of cellular materials, which are known for their thermal and mechanical benefits. Herein, we studied the mechanical behavior of stainless-steel (AISI 316L) lattice structures both experimentally and computationally. The lattice architectures were body-centered cubic, hexagonal vertex centroid, and tetrahedron in two cell sizes and at two different rotation angles. A preliminary computational study assessed the deformation behavior of porous cylindrical samples under compression. After the simulation results, selected samples were manufactured via laser powder bed fusion. The results showed the effects of the pore architecture, unit cell size, and orientation on the reduction in the mechanical properties. The relative densities between 23% and 69% showed a decrease in the bulk material stiffness up to 93%. Furthermore, the different rotation angles resulted in a similar porosity level but different stiffnesses. The simulation analysis and experimental results indicate that the variation in the strut position with respect to the force affected the deformation mechanism. The tetrahedron unit cell showed the smallest variation in the elastic modulus and off-axis displacements due to the cell orientation. This study collected computational and experimental data for tuning the mechanical properties of lattice structures by changing the geometry, size, and orientation of the unit cell.

Deformation characteristics of solid-state benzene as a step towards understanding planetary geology

Small organic molecules, like ethane and benzene, are ubiquitous in the atmosphere and surface of Saturn's largest moon Titan, forming plains, dunes, canyons, and other surface features. Understanding Titan's dynamic geology and designing future landing missions requires sufficient knowledge of the mechanical characteristics of these solid-state organic minerals, which is currently lacking. To understand the deformation and mechanical properties of a representative solid organic material at space-relevant temperatures, we freeze liquid micro-droplets of benzene to form ~10 μm-tall single-crystalline pyramids and uniaxially compress them in situ. These micromechanical experiments reveal contact pressures decaying from ~2 to ~0.5 GPa after ~1 μm-reduction in pyramid height. The deformation occurs via a series of stochastic (~5-30 nm) displacement bursts, corresponding to densification and stiffening of the compressed material during cyclic loading to progressively higher loads. Molecular dynamics simulations reveal predominantly plastic deformation and densified region formation by the re-orientation and interplanar shear of benzene rings, providing a two-step stiffening mechanism. This work demonstrates the feasibility of in-situ cryogenic nanomechanical characterization of solid organics as a pathway to gain insights into the geophysics of planetary bodies.

Nature-inspired architected materials using unsupervised deep learning

Nature-inspired material design is driven by superior properties found in natural architected materials and enabled by recent developments in additive manufacturing and machine learning. Existing approaches to push design beyond biomimicry typically use supervised deep learning algorithms to predict and optimize properties based on experimental or simulation data. However, these methods constrain generated material designs to abstracted labels and to “black box” outputs that are only indirectly manipulable. Here we report an alternative approach using an unsupervised generative adversarial network (GAN) model. Training the model on unlabeled data constructs a latent space free of human intervention, which can then be explored through seeding, image encoding, and vector arithmetic to control specific parameters of de novo generated material designs and to push them beyond training data distributions for broad applicability. We illustrate this end-to-end with new materials inspired by leaf microstructures, showing how biological 2D structures can be used to develop novel architected materials in 2 and 3 dimensions. We further utilize a genetic algorithm to optimize generated microstructures for mechanical properties, operating directly on the latent space. This approach allows for transfer of information across manifestations using the latent space as mediator, opening new avenues for exploration of nature-inspired materials.

Shen and colleagues reported an unsupervised generative adversarial network (GAN) to identify patterns in leaves associated with superior mechanical properties and use 3D printing to build architected materials inspired by the patterns. In the future, this approach may be applied more broadly to natural materials to enable efficient algorithmic construction of structures with customized properties and form factors.

Preparation and Performance of Water-Active Polyurethane Grouting Material in Engineering: A Review

Polyurethane foam materials have broad application prospects in practical engineering as flame retardants, waterproof coatings, and grout repair materials due to advantages such as light weight, quick forming, and good durability. Due to water's low cost and convenience, water-reactive Polyurethane foam materials are widely used in engineering. The content of the water has a significant effect on the performance of polyurethane foams after molding. Polyurethane foams with anti-seepage and reinforcement effects are used in complex water environments for long durations. This study analyzed the effects of water content on properties and the diffusion mechanism of polyurethane foam materials in water. Additionally, the effect of the water environment on the polyurethane grouting material's properties was summarized. Finally, this study discussed the future research directions of polyurethane foam materials in a water environment.

Customizing the mechanical properties of additively manufactured metallic meta grain structure with sheet-based gyroid architecture

The use of cellular structures has led to unprecedented outcomes in various fields involving optical and mechanical cloaking, negative thermal expansion, and a negative Poisson's ratio. The unique characteristics of periodic cellular structures primarily originate from the interconnectivity, periodicity, and unique design of the unit cells. However, the periodicity often induces unfavorable mechanical behaviors such as a "post-yielding collapse", and the mechanical performance is often limited by the design of the unit cells. Therefore, we propose a novel structure called a meta grain structure (MGS), which is inspired by a polycrystalline structure, to enhance flexibility in design and mechanical reliability. A total of 138 different MGSs were built and tested numerically, and the correlations between the design parameters (e.g., the relative density) and mechanical properties of the MGSs were rigorously analyzed. A systematic design methodology was developed to obtain the optimal design of the MGS with the target Young's modulus. This methodology makes it possible to build a unique structure that offers various design options and overcomes the current limitations of cellular structures. Furthermore, a systematic inverse design methodology makes it possible to produce an MGS that satisfies the required mechanical performance.

Mechanical Characterisation and Numerical Modelling of TPMS-Based Gyroid and Diamond Ti6Al4V Scaffolds for Bone Implants: An Integrated Approach for Translational Consideration

Additive manufacturing has been used to develop a variety of scaffold designs for clinical and industrial applications. Mechanical properties (i.e., compression, tension, bending, and torsion response) of these scaffolds are significantly important for load-bearing orthopaedic implants. In this study, we designed and additively manufactured porous metallic biomaterials based on two different types of triply periodic minimal surface structures (i.e., gyroid and diamond) that mimic the mechanical properties of bone, such as porosity, stiffness, and strength. Physical and mechanical properties, including compressive, tensile, bending, and torsional stiffness and strength of the developed scaffolds, were then characterised experimentally and numerically using finite element method. Sheet thickness was constant at 300 μm, and the unit cell size was varied to generate different pore sizes and porosities. Gyroid scaffolds had a pore size in the range of 600-1200 μm and a porosity in the range of 54-72%, respectively. Corresponding values for the diamond were 900-1500 μm and 56-70%. Both structure types were validated experimentally, and a wide range of mechanical properties (including stiffness and yield strength) were predicted using the finite element method. The stiffness and strength of both structures are comparable to that of cortical bone, hence reducing the risks of scaffold failure. The results demonstrate that the developed scaffolds mimic the physical and mechanical properties of cortical bone and can be suitable for bone replacement and orthopaedic implants. However, an optimal design should be chosen based on specific performance requirements.

Shaping 90 wt% NanoMOFs into Robust Multifunctional Aerogels Using Tailored Bio-Based Nanofibrils

Metal-organic frameworks (MOFs) are hybrid porous crystalline networks with tunable chemical and structural properties. However, their excellent potential is limited in practical applications by their hard-to-shape powder form, making it challenging to assemble MOFs into macroscopic composites with mechanical integrity. While a binder matrix enables hybrid materials, such materials have a limited MOF content and thus limited functionality. To overcome this challenge, nanoMOFs are combined with tailored same-charge high-aspect-ratio cellulose nanofibrils (CNFs) to manufacture robust, wet-stable, and multifunctional MOF-based aerogels with 90 wt% nanoMOF loading. The porous aerogel architectures show excellent potential for practical applications such as efficient water purification, CO₂ and CH₄ gas adsorption and separation, and fire-safe insulation. Moreover, a one-step carbonization process enables these aerogels as effective structural energy-storage electrodes. This work exhibits the unique ability of high-aspect-ratio CNFs to bind large amounts of nanoMOFs in structured materials with outstanding mechanical integrity-a quality that is preserved even after carbonization. The demonstrated process is simple and fully discloses the intrinsic potential of the nanoMOFs, resulting in synergetic properties not found in the components alone, thus paving the way for MOFs in macroscopic multifunctional composites.

A Novel Design Method of Gradient Porous Structure for Stabilized and Lightweight Mandibular Prosthesis

Compared to conventional prostheses with homogenous structures, a stress-optimized functionally gradient prosthesis will better adapt to the host bone due to its mechanical and biological advantages. Therefore, this study aimed to investigate the damage resistance of four regular lattice scaffolds and proposed a new gradient algorithm for stabilized and lightweight mandibular prostheses. Scaffolds with four configurations (regular hexahedron, regular octahedron, rhombic dodecahedron, and body-centered cubic) having different porosities underwent finite element analysis to select an optimal unit cell. Meanwhile, a homogenization algorithm was used to control the maximum stress and increase the porosity of the scaffold by adjusting the strut diameters, thereby avoiding fatigue failure and material wastage. Additionally, the effectiveness of the algorithm was verified by compression tests. The results showed that the load transmission capacity of the scaffold was strongly correlated with both configuration and porosity. Scaffolds with regular hexahedron unit cells can withstand stronger loads at the same porosity. The optimized gradient scaffold showed higher porosity and lower maximum stress than the target stress value, and the compression tests also confirmed the simulation results. A mandibular prosthesis was established using a regular hexahedron unit cell, and the strut diameters were gradually changed according to the proposed algorithm and the simulation results. Compared with the initial homogeneous prosthesis, the optimized gradient prosthesis reduced the maximum stress by 24.48% and increased the porosity by 6.82%, providing a better solution for mandibular reconstruction.

Superelastic graphene aerogel-based metamaterials

Ultralight, ultrastrong, and supertough graphene aerogel metamaterials combining with multi-functionalities are promising for future military and domestic applications. However, the unsatisfactory mechanical performances and lack of the multiscale structural regulation still impede the development of graphene aerogels. Herein, we demonstrate a laser-engraving strategy toward graphene meta-aerogels (GmAs) with unusual characters. As the prerequisite, the nanofiber-reinforced networks convert the graphene walls’ deformation from the microscopic buckling to the bulk deformation during the compression process, ensuring the highly elastic, robust, and stiff nature. Accordingly, laser-engraving enables arbitrary regulation on the macro-configurations of GmAs with rich geometries and appealing characteristics such as large stretchability of 5400% reversible elongation, ultralight specific weight as small as 0.1 mg cm⁻³, and ultrawide Poisson’s ratio range from −0.95 to 1.64. Additionally, incorporating specific components into the pre-designed meta-structures could further achieve diversified functionalities.

Graphene aerogels are highly porous and have very low density; despite this they also exhibit high mechanical strength. Here the authors present a laser-engraving strategy for producing graphene meta-aerogels with different configurations and properties.

Urethane-Foam-Embedded Silicon Pressure Sensors including Stress-Concentration Packaging Structure for Driver Posture Monitoring

We propose urethane-foam-embedded silicon pressure sensors, including a stress-concentration packaging structure, for integration into a car seat to monitor the driver’s cognitive state, posture, and driving behavior. The technical challenges of embedding silicon pressure sensors in urethane foam are low sensitivity due to stress dispersion of the urethane foam and non-linear sensor response caused by the non-uniform deformation of the foam. Thus, the proposed package structure includes a cover to concentrate the force applied over the urethane foam and frame to eliminate this non-linear stress because the outer edge of the cover receives large non-linear stress concentration caused by the geometric non-linearity of the uneven height of the sensor package and ground substrate. With this package structure, the pressure sensitivity of the sensors ranges from 0 to 10 kPa. The sensors also have high linearity with a root mean squared error of 0.049 N in the linear regression of the relationship between applied pressure and sensor output, and the optimal frame width is more than 2 mm. Finally, a prototype 3 × 3 sensor array included in the proposed package structure detects body movements, which will enable the development of sensor-integrated car seats.

Composite design bioinspired by the mesocarp of Brazil nut (Bertholletia excelsa)

The mesocarp ofBertholletia excelsais a rich source of inspiration for strong, stiff and damage-tolerant composites. The bioinspired composites developed here are composed of an epoxy matrix with a 3D printed polylactic acid reinforced with 30% of carbon fiber (PLA-30CF) inspired in fibers, and syntactic foam inspired by sclereids. Monotonic and cyclic four-point bending tests and compact tension fracture toughness tests were carried out assisted by digital image correlation (DIC) to evaluate flexural properties, damage tolerance, and theR-curve of the composite. Its microstructure and fracture surface were analyzed by scanning electron microscopy. The mechanical performance of the bioinspired composite is promising: density of 1.0 g cm^-3, flexural apparent elastic modulus of 1.6 GPa, and flexural strength six times higher than the neat epoxy, i.e. 17 MPa. Although the PLA-30CF printed structure led to a risingR-curve, the syntactic foam needs optimization to have a synergistic effect.

Hyphal systems and their effect on the mechanical properties of fungal sporocarps

Little is known about the mechanical and material properties of hyphae, the single constituent material of Agaricomycetes fungi, despite a growing interest in fungus-based materials. In the Agaricomycetes (the mushrooms and allies), there are three types of hyphae that make up sporocarps: generative, skeletal, and ligative. All filamentous Agaricomycetes can be categorized into one of three categories of hyphal systems that compose them: monomitic, dimitic, and trimitic. Monomitic systems have only generative hyphae. Dimitic systems have generative and either skeletal (most common) or ligative. Trimitic systems are composed of all three kinds of hyphae. SEM imaging, compression testing, and theoretical modeling were used to characterize the material and mechanical properties of representative monomitic, dimitic, and trimitic sporocarps. Compression testing revealed an increase in the compression modulus and compressive strength with the addition of more hyphal types (monomitic to dimitic and dimitic to trimitic). The mesostructure of the trimitic sporocarp was tested and modeled, suggesting that the difference in properties between the solid material and the microtubule mesostructure is a result of differences in structure and not material. Theoretical modeling was completed to estimate the mechanical properties of the individual types of hyphae and showed that skeletal hyphae make the largest contribution to mechanical properties of fungal sporocarps. Understanding the contributions of the different types of hyphae may help in the design and application of fungi-based or bioinspired materials. STATEMENT OF SIGNIFICANCE: This research studies the material and mechanical properties of fungal sporocarps and their hyphae, the single constituent material of Agaricomycetes fungi. Though some work has been done on fungal hyphae, this research studies hyphae in context of the three hyphal systems found in Agaricomycetes fungi and estimates the properties of the hyphal filaments, which has not been done previously. This characterization was performed by analyzing the structures and mechanical properties of fungal sporocarps and calculating the theoretical mechanical properties of their hyphae. This data and the resulting conclusions may lead to a better design and implementation process of fungi-based materials in various applications using the properties now known or calculated.

Influence of almond and coconut flours on Ketogenic, Gluten-Free cupcakes

Ketogenic, gluten-free cupcakes containing varying amounts of almond and coconut flours were evaluated for textural and sensory attributes. Coconut-flour particle-size influenced cupcake volume and crumb structure, with smaller flour-particle size resulting in increased volume and decreased crumb density. Although almond-flour particle size itself did not directly influence cupcake properties, volume increases were observed in cupcakes with higher percentages of almond flour. Addition of coconut flour increased cell size and decreased cell density. Mechanical testing showed almond flour resulted in a cupcake that was more tender. Adhesion and cohesion values showed no statistical difference after 24 h and minimal change at subsequent evaluation periods. Quantitative descriptive analysis and consumer acceptance evaluation indicated that cupcakes containing almond flour were more moist and tender, and were preferred over cupcakes made with only coconut flour. Almond and coconut flours may be used in gluten-free, ketogenic cupcakes, with almond flour performing better in evaluated parameters.

Comparing Carbon Origami from Polyaramid and Cellulose Sheets

Carbon origami enables the fabrication of lightweight and mechanically stiff 3D complex architectures of carbonaceous materials, which have a high potential to impact a wide range of applications positively. The precursor materials and their inherent microstructure play a crucial role in determining the properties of carbon origami structures. Here, non-porous polyaramid Nomex sheets and macroporous fibril cellulose sheets are explored as the precursor sheets for studying the effect of precursor nature and microstructure on the material and structural properties of the carbon origami structures. The fabrication process involves pre-creasing precursor sheets using a laser engraving process, followed by manual-folding and carbonization. The cellulose precursor experiences a severe structural shrinkage due to its macroporous fibril morphology, compared to the mostly non-porous morphology of Nomex-derived carbon. The morphological differences further yield a higher specific surface area for cellulose-derived carbon. However, Nomex results in more crystalline carbon than cellulose, featuring a turbostratic microstructure like glassy carbon. The combined effect of morphology and glass-like features leads to a high mechanical stiffness of 1.9 ± 0.2 MPa and specific modulus of 2.4 × 10⁴ m²·s⁻² for the Nomex-derived carbon Miura-ori structure, which are significantly higher than cellulose-derived carbon Miura-ori (elastic modulus = 504.7 ± 88.2 kPa; specific modulus = 1.2 × 10⁴ m²·s⁻²) and other carbonaceous origami structures reported in the literature. The results presented here are promising to expand the material library for carbon origami, which will help in the choice of suitable precursor and carbon materials for specific applications.

Generative machine learning algorithm for lattice structures with superior mechanical properties

Lattice structures are typically made up of a crisscross pattern of beam elements, allowing engineers to distribute material in a more structurally effective way. However, a main challenge in the design of lattice structures is a trade-off between the density and mechanical properties. Current studies have often assumed the cross-sectional area of the beam elements to be uniform for reducing the design complexity. This simplified approach limits the possibility of finding superior designs with optimized weight-to-performance ratios. Here, the optimized shape of the beam elements is investigated using a deep learning approach with high-order Bézier curves to explore the augmented design space. This is then combined with a hybrid neural network and genetic optimization (NN-GO) adaptive method for the generation of superior lattice structures. In our optimized design, the distribution of material is smartly shifted more towards the joint region, the weakest location of lattice structures, to achieve the highest modulus and strength. This design strikes to balance between two modes of deformation: axial and bending. Thus, the optimized design is efficient for load bearing and energy absorption. To validate our simulations, the optimized design is then fabricated by additive manufacturing and its mechanical properties are evaluated through compression testing. A good correlation between experiments and simulations is observed and the optimized design has outperformed benchmark ones in terms of modulus and strength. We show that the extra design flexibility from high-order Bézier curves allows for a smoother transition between the beam elements which reduces the overall stress concentration profile.

Mechanical Properties and Energy-Absorption Capability of a 3D-Printed TPMS Sandwich Lattice Model for Meta-Functional Composite Bridge Bearing Applications

This paper reports on a proposed novel 3D-printed sandwich lattice model using a triply periodic minimal surface (TPMS) structure for meta-functional composite bridge bearings (MFCBBs). It could be implemented in bridge systems, including buildings and railway bridges. A TMPS structure offers a high performance to density ratio under different loading. Compared to typical elastomeric bridge bearings with any reinforcements, the use of 3D-printed TPMS sandwich lattices could potentially lead to a substantial reduction in both manufacturing cost and weight, but also to a significant increase in recyclability with their better mechanical properties (compressive, crushing, energy absorption, vibration, and sound attenuation). This paper shows predictions from a numerical study performed to examine the behaviour of a TPMS sandwich lattice model under two different loading conditions for bridge bearing applications. The validation of the modelling is compared with experimental results to ensure the possibility of designing and fabricating a 3D-printed TPMS sandwich lattice for practical use. In general, the compressive experimental and numerical load–displacement behaviour of the TPMS unit cell are in excellent agreement within the elastic limit region. Moreover, its failure mode for bridge bearing applications has been identified as an elastic–plastic and hysteretic failure behaviour under uniaxial compression and combined compression–shear loading, respectively.

Approach to quantify the resistance of polymeric foams against thermal load under compression

Nowadays, numerous techniques are used to quantify the resistance of cellular polymers against a thermal load. These techniques differ in significance and reproducibility and are all dependent on foam density, structure (i.e., cell size and -distribution) and sample geometry. Very different behaviors are expected for extrusion- and bead foams, as well as for amorphous and semi-crystalline polymers. Moreover, established tests use temperature ramps which would lead to temperature gradients within the sample and thus to faulty results. In this study, we developed a new approach from an engineering perspective to minimize these influences. In this approach, the resistance against the thermal load is derived from a steady creep test with defined temperature steps under a mechanical load, which is specifically set for each foam sample depending on its static compression behavior at room temperature. The two-stage test therefore combines (i) a standard quasi-static compression test at room temperature and (ii) a creep test with stepwise increased thermal loading. For each foam type, a rather low mechanical load (stress) is determined from the quasi-static compression test at room temperature; low enough to remain below the collapse strength and avoid irreversible deformation (i.e., buckling and/or breaking of the cell walls). This load is then applied in a creep test where the temperature is increased in defined steps from room temperature to a temperature close to T g or T m . The stepwise increase and holding of the temperature for a defined time enables a homogeneous temperature in the test specimen. The approach was applied to (i) polystyrene extrusion and bead foams (i.e., XPS and EPS), which have different foam structure, (ii) amorphous and semi-crystalline bead foams of polystyrene (EPS) and polypropylene (EPP), (iii) bead foams with different densities (30, 60, 120, and 210 kg/m3) and (iv) to a new type of bead foam made of the engineering polymer polybutylene terephthalate (E-PBT). The termination criterion for the test is defined as the temperature at which a relative compression of 10% is reached in the creep test with temperature steps. We suggest calling it the heat stability temperature T HS. For the studied foams, the procedure delivers characteristic T HS values that allow a good comparison between different polymer matrices and densities. The heat stability temperature T HS of amorphous PS foams (i.e., XPS and EPS) was determined to be 98 °C, which is close to the glass transition temperature T g . Using the same approach, values of 99–107 °C were determined for EPP and 186 °C for the semi-crystalline bead foam E-PBT.