Generative Design of 3D-Printed Biomimetic Interlocking Blocks Inspired by the Cellular 3D Puzzle Structure of the...

Area of Science:

• Biomimetics and Materials Science
• Structural Engineering
• Computational Design

Background:

• Walnut shell microstructure features specialized cells (sclereids) with protrusions that interlock.
• This interlocking mechanism provides exceptional toughness through increased surface contact.
• Understanding and emulating this natural design can lead to advanced engineered materials.

Purpose of the Study:

• To apply a novel biomimetic design strategy inspired by walnut shell microstructure.
• To analyze, emulate, and technically evaluate design solutions based on natural morphogenetic logic.
• To enhance the mechanical behavior of interlocking systems through interfacial geometry optimization.

Main Methods:

• Developed a generative algorithm using an evolutionary solver (Galapagos) and visual programming (Grasshopper).
• Algorithm generated protrusions on structural block interfaces, optimizing contact surface area.
• Fabricated specimens using fused filament fabrication (FFF) with PLA and conducted three-point bending tests.

Main Results:

• Increasing protrusion number significantly enhanced mechanical performance.
• Increasing protrusion height improved stiffness and interlocking up to a threshold, beyond which performance decreased.
• Computational models showed good agreement with experimental results, validating the biomimetic approach.

Conclusions:

• Biomimetic optimization of interfacial geometry enhances mechanical behavior in interlocking systems.
• The study provides a framework for translating biological morphogenetic principles into engineering applications.
• This approach offers a pathway to designing tougher and stiffer engineered materials.