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Elastic meta-materials, which we will treat herein as synonymous with elastic micro-architected materials, derive their unique combination of properties from the fine scale geometry of their solid and void regions. Recent advances in additive manufacturing have made the fabrication of such micro-architected materials feasible, and have driven interest in their properties. We consider the class of elastic meta-materials whose micro-architectures are composed of a network of straight struts connected at nodes arranged within a repeating unit cell; the octet truss is one well-known example of such truss lattices. Heretofore, the majority of work characterizing such truss lattices has considered solid struts and has been based on rod theory, a simplification of continuum elasticity which is accurate in the limit of low relative densities. In this paper, we use full continuum theory, solved with finite element analysis on adaptively refined meshes, to characterize the elastic performance of seven truss lattices with cubic geometric symmetry, and whose struts and nodes are hollow; we consider a wide range of strut wall thicknesses and truss relative densities. Varying the wall thickness provides an additional dimension of control, so that stiffness and anisotropy can, to an extent, be decoupled from the relative density of a given truss lattice. We show that a truss’ stiffness can be increased at fixed relative density, with bend-dominated truss lattices showing significantly greater improvement than stretch-dominated designs. Increases in stiffness by a factor of greater than five are observed, and increases by a factor of 100 or more are obtainable. Bend-dominated structures with hollow struts can be found that are stiffer than stretch-dominated ones at nearly all relative densities, contradicting a common rule of thumb. For some trusses, including the octet truss, choosing the wall thickness appropriately allows one to obtain isotropic response over a large range of volume fractions. We use topology optimization to find maximally stiff multiscale structures comprised of micro-architected materials and find that all the trusses we consider perform similarly, with anisotropic trusses resulting in slightly stiffer structures for a given load.

Elastic meta-materials are those whose unique properties come from their micro-architecture, rather than, e.g., from their chemistry. The introduction of such architecture, which is increasingly able to be fabricated due to advances in additive manufacturing, expands the design domain and enables improved design, from the most complex multi-physics design problems to the simple compliance design problem that is our focus. Unfortunately, concurrent design of both the micro-scale and the macroscale is computationally very expensive when the former can vary spatially, particularly in three dimensions. Instead, we provide simple, accurate surrogate models of the homogenized linear elastic response of the isotruss, the octet truss, and the ORC truss based on high-fidelity continuum finite element analyses. These surrogate models are relatively accurate over the full range of relative densities, in contrast to analytical models in the literature, which we show lose accuracy as relative density increases. The surrogate models are also simple to implement, which we demonstrate by modifying Sigmund’s 99-line code to solve a three-dimensional, multiscale compliance design problem with spatially varying relative density. We use this code to generate examples in both two and three dimensions that illustrate the advantage of elastic meta-materials over structures with a single length scale, i.e., those without micro-architectures.

The present paper focuses on solving partial differential equations in domains exhibiting symmetries and periodic boundary conditions for the purpose of homogenization. We show in a systematic manner how the symmetry can be exploited to significantly reduce the complexity of the problem and the computational burden. This is especially relevant in inverse problems, when one needs to solve the partial differential equation (the primal problem) many times in an optimization algorithm. The main motivation of our study is inverse homogenization used to design architected composite materials with novel properties which are being fabricated at ever increasing rates thanks to recent advances in additive manufacturing. For example, one may optimize the morphology of a two-phase composite unit cell to achieve isotropic homogenized properties with maximal bulk modulus and minimal Poisson ratio. Typically, the isotropy is enforced by applying constraints to the optimization problem. However, in two dimensions, one can alternatively optimize the morphology of an equilateral triangle and then rotate and reflect the triangle to form a space filling D 3 symmetric hexagonal unit cell that necessarily exhibits isotropic homogenized properties. One can further use this D 3 symmetry to reduce the computational expense by performing the “unit strain” periodic boundary condition simulations on the single triangle symmetry sector rather than the six fold larger hexagon. In this paper we use group representation theory to derive the necessary periodic boundary conditions on the symmetry sectors of unit cells. The developments are done in a general setting, and specialized to the two-dimensional dihedral symmetries of the abelian D 2 , i.e. orthotropic, square unit cell and nonabelian D 3 , i.e. trigonal, hexagon unit cell. We then demonstrate how this theory can be applied by evaluating the homogenized properties of a two-phase planar composite over the triangle symmetry sector of a D 3 symmetric hexagonal unit cell.

We validate the predicted performance of new lattice materials that are stiff despite appearing to violate the Maxwell criterion., Materials with a stochastic microstructure, like foams, typically exhibit low mechanical stiffness, whereas lattices with a designed microarchitecture often show notably improved stiffness. These periodic architected materials have previously been designed by rule, using the Maxwell criterion to ensure that their deformation is dominated by the stretching of their struts. Classical designs following this rule tend to be anisotropic, with stiffness depending on the load orientation, but recently, isotropic designs have been reported by superimposing complementary anisotropic lattices. We have designed stiff isotropic lattices de novo with topology optimization, an approach based on continuum finite element analysis. Here, we present results of experiments on these lattices, fabricated by additive manufacturing, that validate predictions of their performance and demonstrate that they are as efficient as those designed by rule, despite appearing to violate the Maxwell criterion. These findings highlight the enhanced potential of topology optimization to design materials with unprecedented properties.