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[Display omitted] • Pyramidal lattice structures (PLS) with I-shaped struts were 3D printed via DLP. • The utilization of I-shaped struts led to an increase in energy absorption of up to 68%. • Lateral buckling of the lattice struts was observed in the tailored PLS. • The measurements and observed collapse modes were in good agreement with FE predictions. • Specific cross-sectional designs can achieve enhancements in strength of up to 93%. This study examines the compressive response of geometrically tailored pyramidal lattice structures composed of struts with I-shaped cross-sections. Geometrically tailored pyramidal lattices with micro-scale features are 3D printed using the Digital Light Processing (DLP) technique, and their effective elastic modulus, collapse strength and energy absorption capacity are experimentally evaluated under quasi-static compressive loading. Furthermore, detailed non-linear finite element (FE) calculations are performed to examine underlying collapse mechanisms and explore the vast design space offered by the proposed geometrical tailoring scheme. Both the experimental and numerical results show that the geometrically tailored lattice structures outperform conventional pyramidal lattices of equal weight in terms of elastic modulus (+24 %), collapse strength (+21 %) and energy absorption (+68 %). Notably, these strength improvements are attributed to lateral buckling that prompts the I-shaped struts to bend sideways during collapse. Specific cross-sectional designs demonstrate remarkable enhancements in strength and energy absorption, reaching up to 93 % and 161 %, respectively, differentiating them significantly from conventional designs. [ABSTRACT FROM AUTHOR]

[Display omitted] • Porous bone plates with cubic (C), diamond (BCC) and body-centered cubic (CBCC) structures were prepared. • Axial compression, torsional and bending tests were carried out to check the designs' reliability. • CBCC structure with enhanced performance was used with varying rows' and porosities. • Finite element analysis was used to check the biomechanical performance of bone plates. • Increased porosity enhanced the callus volume but displayed poor mechanical performance. The current study investigates the biomechanical performance of porous bone plates augmented with three different cellular lattice structures, e.g., body-centered cube (BCC), simple cube (SC), and the superposition of simple and body-centered cube (SC-BCC) structures. The SC-BCC cellular structures, exhibiting improved torsional, compression, and bending stiffness, were strategically integrated into the bone plates. Configurations ranging from one to three rows, with porosity ranging from 30% to 90%. Increasing the number of rows and porosity maximized the interfragmentary movement at the fracture site. Specifically, SC-BCC configurations with one, two and three rows at 90% porosity demonstrated callus volume improvements of 31.33%, 42%, and 43.2%, respectively, compared with the lowest callus volume observed with SC-BCC at one row and 30% porosity. Regardless of the improved volume, callus stiffness was highest at 30% and 90% porosity levels across all cases, indicating more mature tissue formation in calluses and better physiological load support. High stresses located at 90% porosity, followed by 50% porosity, discouraged their mechanical performance. Therefore, employing 30% porosity configurations with appropriate vertical rows for desired movement is recommended for optimal biomechanical performance. However, 90% porosity may be suitable in scenarios involving minimal forces and restricted patient movement. [ABSTRACT FROM AUTHOR]