Scalable Hierarchically Structured Materials from a Multiscale Particle System Enabled by Microscaffolds

Structural hierarchy is the key to manufacturing multiscale particle-based composite materials. A novel manufacturing method was developed to generate scalable hierarchical structures in concrete. The new method used 3D-printed microscaffolds to interact with the multiscale particle packing in concrete, resulting in a structured lightweight composite material. The size of internal members can vary by more than two orders of magnitude, to adapt to different applications. Based on compression tests and microstructural investigation by optical microscope and quantitative nanomechanical mapping, we found that the new material is 63.93% more efficient in energy absorption capacity compared with traditional lightweight concrete. Our experimental trials also showed that introducing structural hierarchy can reduce the consumption of cementitious material in the system by up to 14% and significantly reduce the use of scaffolds. The method could be applied to a board spectrum of multiscale particle-based materials, such as dental cement and bone implant materials, to improve material performance and efficiency in medical and construction applications.