Optimized mechano-fluidic metamaterials inspired by deep-sea sponges

Multifunctional materials that balance mechanical resilience and fluid dynamic efficiency are critical in engineering applications, yet their synergistic optimization remains challenging due to inherent trade-offs, computational expense, and high-dimensional design spaces. Inspired by the skeleton of the deep-sea sponge Euplectella aspergillum, this work presents an automated framework integrating Finite Element Analysis for mechanics, Computational Fluid Dynamics for flow behavior, and multi-objective Bayesian optimization. Leveraging high-performance computing, the framework efficiently explores complex design spaces to identify Pareto-optimal solutions. Optimized lattices achieve an average 140% increase in critical buckling load across a range of volume fractions relative to baseline designs, while simultaneously reducing drag, lift, and vortex shedding at porosities as low as 5%. We fabricate selected designs via stereolithography and validate them through compression experiments and particle image velocimetry, showing agreement with simulations. By jointly optimizing mechanics and fluidics, this work establishes a scalable methodology for designing lightweight, high-performance architected materials.