Architected lattice materials are some of the stiffest and strongest materials at ultra‐light density (<10 mg cm−3), but scalable manufacturing with high‐performance constituent materials remains a challenge that limits their widespread adoption in load‐bearing applications. We show mesoscale, ultra‐light (5.8 mg cm−3) fiber‐reinforced polymer composite lattice structures that are reversibly assembled from building blocks manufactured with a best‐practice high‐precision, high‐repeatability, and high‐throughput process: injection molding. Chopped glass fiber‐reinforced polymer (polyetherimide) lattice materials produced with this method display absolute stiffness (8.41 MPa) and strength (19 kPa) typically associated with metallic hollow strut microlattices at similar mass density. Additional benefits such as strain recovery, discrete damage repair with recovery of original stiffness and strength, and ease of modeling are demonstrated.

Ultralight materials present an opportunity to dramatically increase the efficiency of load-bearing aerostructures. To date, however, these ultralight materials have generally been confined to the laboratory bench-top, due to dimensional constraints of the manufacturing processes. We show a programmable material system applied as a large-scale, ultralight, and conformable aeroelastic structure. The use of a modular, lattice-based, ultralight material results in stiffness typical of an elastomer (2.6 MPa) at a mass density typical of an aerogel 5.6 mg cm 3 (). This, combined with a building block based manufacturing and configuration strategy, enables the rapid realization of new adaptive structures and mechanisms. The heterogeneous design with programmable anisotropy allows for enhanced elastic and global shape deformation in response to external loading, making it useful for tuned fluid-structure interaction. We demonstrate an example application experiment using two building block types for the primary structure of a 4.27 m wingspan aircraft, where we spatially program elastic shape morphing to increase aerodynamic efficiency and improve roll control authority, demonstrated with full-scale wind tunnel testing.

Abstract. Real world systems that are candidates for vibrational energy harvesting rarely vibrate at a single frequency, nor are these frequencies constant over time. This necessitates that vibration harvesters operate over a wide bandwidth or tune their resonance. Most tunable devices require additional energy or active control to achieve resonance over various frequencies. This work presents a passively self-tuning energy harvester that autonomously adapts its resonant frequency to the input without requiring additional energy. The system consists of a clampedclamped beam, a movable proof mass, and a piezoelectric patch bonded to the underside of the beam. It demonstrated an open-circuit voltage output of 668 mVrms at 160Hz, 0.65g input excitation. Discrepancies between displacement and voltage magnification factors upon tuning at higher frequencies are discussed, as well as instabilities of the system and sensitivity to proof mass characteristics.

We present a modular, reconfigurable system for building large structures. This system uses discrete lattice elements, called digital materials, to reversibly assemble ultralight structures that are 99.7% air and yet maintain sufficient specific stiffness for a variety of structural applications and loading scenarios. Design, manufacturing, and characterization of modular building blocks are described, including struts, nodes, joints, and build strategies. Simple case studies are shown using the same building blocks in three different scenarios: a bridge, a boat, and a shelter. Field implementation and demonstration is supplemented by experimental data and numerical simulation. A simplified approach for analyzing these structures is presented which shows good agreement with experimental results.

We describe a system for the design of space structures with tunable structural properties based on the discrete assembly of modular lattice elements. These lattice elements can be constructed into larger beam-like elements, which can then be assembled into large scale truss structures. These discrete lattice elements are reversibly assembled with mechanical fasteners, which allows them to be arbitrarily reconfigured into various application-specific designs. In order to assess the validity of this approach, we design two space structures with similar geometry but widely different structural requirements: an aerobrake, driven by strength requirements, and a precision segmented reflector, driven by stiffness and accuracy requirements. We will show agreement between simplified numerical models based on hierarchical assembly and analytical solutions. We will also present an assessment of the error budget resulting from the assembly of discrete structures. Lastly, we will address launch vehicle packing efficiency issues for transporting these structures to lower earth orbit.

The accidental untying of a shoelace while walking often occurs without warning. In this paper, we discuss the series of events that lead to a shoelace knot becoming untied. First, the repeated impact of the shoe on the floor during walking serves to loosen the knot. Then, the whipping motions of the free ends of the laces caused by the leg swing produce slipping of the laces. This leads to eventual runaway untangling of the knot. As demonstrated using slow-motion video footage and a series of experiments, the failure of the knot happens in a matter of seconds, often without warning, and is catastrophic. The controlled experiments showed that increasing inertial effects of the swinging laces leads to increased rate of knot untying, that the directions of the impact and swing influence the rate of failure, and that the knot structure has a profound influence on a knot's tendency to untie under cyclic impact loading.

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We describe analytical methods for the design of the discrete elements of ultralight lattice structures. This modular, building block strategy allows for relatively simple element manufacturing, as well as relatively simple robotic assembly of low mass density structures on orbit, with potential for disassembly and reassembly into highly varying and large structures. This method also results in a structure that is easily navigable by relatively small mobile robots. The geometry of the cell can allow for high packing efficiency to minimize wasted payload volume while maximizing structural performance and constructability. We describe the effect of geometry choices on the final system mechanical properties and automated robotic constructability of a final system. Geometric properties considered include number of attachments per voxel, number of attachments per coefficient of volume, and effects of vertex, edge, and face connectivity of the unit cell. Mechanical properties considered include strength scaling, modulus scaling, and packing efficiency of the lattice. Automated constructibility metrics include volume allowance for an end-effector, strut clearance angle for an endeffector, and packing efficiency. These metrics were applied to six lattice unit cell geometries: cube, cuboctahedron, octahedron, octet, rhombic dodecahedron, and truncated octahedron. A case study is presented to determine the most suitable lattice system for a specific set of strength and modulus scaling requirements while optimizing for ease of robotic assembly.