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<p>The stringent requirements for functional protective materials are driving innovation in flexible mechanical metamaterials. In this study, we proposed a bionic layered interwoven structure (BLI) based on the doubly periodic continuous surfaces (DPCSs) inspired by the microstructure of the hermit crab chela and developed three gradient design strategies, including thickness gradient (TG), elastic modulus gradient (EG), and hybrid gradient (HG). NiTi-based samples were fabricated using laser powder bed fusion (LPBF) technology, and the manufacturability, phase, compression response, and superelasticity (SE) were investigated. The results indicated that the LPBF process ensured the geometrical fidelity of BLIs, but the manufacturability was challenged by high residual stresses. The mechanical responses of BLIs depended on the properties of the sublayers and their affected zones, and the hybrid gradient exhibited the highest ultimate strength of ∼1.51 MPa and ultimate strain of ∼0.375. Notably, BLIs showed superior mechanical flexibility with an ultra-low modulus of ∼13.9 MPa approaching that of rubber-based triply periodic minimal surface (TPMS), which can be attributed to the combination effect of wavelike deformations, high deformation degree of freedom, and effective stress transfer. The strategic sacrifice of weak sublayers induced a reduction of the actual strain in other regions, leading to the enhancement in the durability of gradient structures. The designs could serve as a reference for the development of metal flexible metamaterials.</p>

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Achieving superior mechanical flexibility and durability in additively manufactured NiTi-based bionic layered interwoven structures

  • 期刊论文

  • 发表日期：

    2025年3月7日

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  • Jianfeng Sun,
  • Dongdong Gu,
  • Ruiqi Wang,
  • Jingjia Sun,
  • Xin Liu,
  • Wenxin Chen,
  • Jie Wang,
  • Keyu Shi

摘要

The stringent requirements for functional protective materials are driving innovation in flexible mechanical metamaterials. In this study, we proposed a bionic layered interwoven structure (BLI) based on the doubly periodic continuous surfaces (DPCSs) inspired by the microstructure of the hermit crab chela and developed three gradient design strategies, including thickness gradient (TG), elastic modulus gradient (EG), and hybrid gradient (HG). NiTi-based samples were fabricated using laser powder bed fusion (LPBF) technology, and the manufacturability, phase, compression response, and superelasticity (SE) were investigated. The results indicated that the LPBF process ensured the geometrical fidelity of BLIs, but the manufacturability was challenged by high residual stresses. The mechanical responses of BLIs depended on the properties of the sublayers and their affected zones, and the hybrid gradient exhibited the highest ultimate strength of ∼1.51 MPa and ultimate strain of ∼0.375. Notably, BLIs showed superior mechanical flexibility with an ultra-low modulus of ∼13.9 MPa approaching that of rubber-based triply periodic minimal surface (TPMS), which can be attributed to the combination effect of wavelike deformations, high deformation degree of freedom, and effective stress transfer. The strategic sacrifice of weak sublayers induced a reduction of the actual strain in other regions, leading to the enhancement in the durability of gradient structures. The designs could serve as a reference for the development of metal flexible metamaterials.