Catenary-inspired 3D hybrid lattice structures and materials: Design and mechanical performance

Abstract

This study presents a novel catenary-inspired 3D hybrid (CCH) lattice structure, and the corresponding lattice materials were fabricated using 3D printing technology. Finite element analysis and experiments on strut length, diameter, and catenary coefficient show that the CCH lattice materials achieve superior mechanical properties and isotropy. Remarkably, sample A1 achieves a specific energy absorption of 16.68 MJ/m³ at the same strain, which represents a 91.94% increase compared with the diamond lattice structure. Within the tested range, the mechanical strength and energy absorption of the CCH lattice materials increase with larger strut diameters and decrease with longer strut lengths and higher catenary coefficients. Lastly, the typical deformation modes are progressive layer-by-layer collapse and uniform crushing, indicating stable energy absorption behavior under loading.