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Updated: Jul 12, 2026
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Characterizing Dissipative Elastic Metamaterials Produced by Additive Manufacturing
Published on: June 28, 2024
A geometry-process-property framework for FDM-fabricated TPU energy-absorbing metamaterials.
Noam Ribak1, Sahar Halevi1, Sivan Hazan1
1Department of Biomedical Engineering, Ben-Gurion University of the Negev, 8499000, Beer-Sheva, Israel.
Scientific Reports
|July 9, 2026
Summary
This study introduces a manufacturability-constrained framework for designing energy-absorbing lattices using 3D printing. It enables the creation of tailored mechanical metamaterials with predictable performance for applications like protective gear.
Area of Science:
- Materials Science
- Mechanical Engineering
- Additive Manufacturing
Background:
- Mechanical metamaterials offer high energy absorption, but design often neglects manufacturability, limiting practical application.
- Existing studies lack transferable design rules for 3D-printed energy-absorbing structures.
Purpose of the Study:
- To develop a framework integrating geometry, manufacturing constraints, and material properties for fused deposition modeling (FDM) lattices.
- To establish a method for generating design rules and performance fingerprints for 3D-printed energy-absorbing metamaterials.
Main Methods:
- A print-constrained framework was developed, embedding manufacturability limits in CAD for FDM-printed thermoplastic polyurethane (TPU) lattices.
- Dimensional metrology, mechanical testing, and finite element analysis validated printed behavior.
- Four curvilinear unit-cell families were fabricated and tested under quasi-static compression.
Main Results:
- Increasing internal angles (up to 45°) enhanced stiffness and energy absorption capacity.
- Unit-cell geometry dictated deformation modes and energy dissipation characteristics.
- Normalized design fingerprints (radar charts) were created to guide architecture selection for specific applications.
Conclusions:
- The framework provides a practical approach for process-aware selection of manufacturable, energy-absorbing lattice architectures.
- The developed design fingerprints facilitate the creation of reusable libraries for tailored metamaterial design.
- The approach was successfully demonstrated for selecting lattices for a scar therapy pressure garment.
