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Updated: Jan 16, 2026

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Density-Based Topology-Optimized 3D-Printed Fixtures for Cyclic Mechanical Testing of Lattice Structures.

Josué Castro1, Rodrigo Valle2, Jorge Leiva3

  • 1Department of Mechanical Engineering, Universidad de La Frontera, Temuco 4811230, Chile.

Polymers
|September 27, 2025
PubMed
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Optimized PLA fixtures ensure accurate cyclic load testing of lattice materials. These 3D-printed supports significantly reduce deformation, improving experimental reliability for architected materials.

Area of Science:

  • Materials Science
  • Mechanical Engineering
  • Additive Manufacturing

Background:

  • Accurate experimental characterization of architected lattice materials under cyclic loading is crucial.
  • Existing fixture systems often introduce parasitic effects, compromising load transfer reliability.
  • There is a need for improved testing fixtures for lattice structures.

Purpose of the Study:

  • To design and validate novel testing fixtures for cyclic load tests on lattice structures.
  • To optimize fixture design using density-based topological optimization.
  • To evaluate the performance of 3D-printed fixtures made from PLA filaments.

Main Methods:

  • Density-based topological optimization was employed to design the testing fixtures.
  • Finite element simulation was used to evaluate the optimized designs.
Keywords:
3D printed fixturesadditive manufacturingcyclic mechanical testinglattice structurestopology optimization

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  • Experimental testing was conducted to validate the performance of the PLA fixtures.
  • Comparison with traditional machine clamps and metal test systems.

    • Main Results:

    • The optimized PLA fixtures achieved a safety factor of 4.25, a significant improvement from the initial 2.08.
    • Deformations were reduced by approximately 80% compared to standard machine clamps.
    • Optimized PLA supports exhibited minimal displacement (around 0.73 mm) under load.
    • Demonstrated rigid and reliable stress transfer to the lattice structure.

    Conclusions:

    • 3D-printed PLA fixtures are viable alternatives to conventional metal devices for mechanical testing of lattice materials.
    • Optimized fixtures ensure accurate load transfer and minimize parasitic effects in cyclic testing.
    • The study confirms the potential of additive manufacturing for creating specialized testing equipment.