Review on Design, Optimization, and Application of Additive Manufacturing for Bioinspired Cellular Structures

Cellular structures consist of a network of interconnected plates, struts, or small unit cells. These structures offer numerous advantages, such as a high strength-to-weight ratio, high energy absorption, minimal material usage, and lightweight properties. Cellular structures can also be thought of as having a cellular architecture. In the additive manufacturing (AM) process, components are designed using computer-aided design, sliced into thin layers, and then the sliced file is transferred to the AM machine to manufacture the component. Unlike conventional techniques, AM technology can produce practically complex geometry, even minuscule cellular structures. These structures are prevalent in many scientific domains, and major industries have taken advantage of them. The review provides an overview of recent developments that have helped promote bioinspired structures. Some structures could be bio-mimicked from horn, balanus shell, DNA, and bottle wings to design cost-effective energy absorbers due to their excellent mechanical properties. This review would provide possible ways for developing novel designs that draw inspiration from biological systems, with a specific focus on their application in energy absorption and the manufacturing methods of cellular structures in industrial applications. The discussion encompasses an in-depth analysis of the advantages offered by additively manufactured structures, along with their potential applications and limitations.