Low Fatigue Dynamic Auxetic Lattices With 3D Printable, Multistable, and Tuneable Unit Cells

Abstract

Stress distribution has led to the design of both tough and lightweight materials. Truss structures distribute stress well and are commonly used to design lightweight materials for applications experiencing low strains. In 3D lattices, however, few structures allow high elastic compression and tunable deformation. This is especially true for auxetic material designs, such as the prototypical re-entrant honeycomb with sharp corners, which are particularly susceptible to stress concentrations. There is a pressing need for lightweight lattice designs that are dynamic, as well as resistant to fatigue. Truss designs based on hinged structures exist in nature and delocalize stress rather than concentrating it in small areas. They have inspired us to develop s-hinge shaped elastic unit cell elements from which new classes of architected modular 2D and 3D lattices can be printed or assembled. These lattices feature locally tunable Poisson ratios (auxetic), large elastic deformations without fatigue, as well as mechanical switching between multistable states. We demonstrate 3D printed structures with stress delocalization that enables macroscopic 30% cyclable elastic strains, far exceeding those intrinsic to the materials that constitute them (6%). We also present a simple semi-analytical model of the deformations which is able to predict the mechanical properties of the structures within <5% error of experimental measurements from a few parameters such as dimensions and material properties. Using this model, we discovered and experimentally verified a critical angle of the s-hinge enabling bistable transformations between auxetic and normal materials. The dynamic modeling tools developed here could be used for complex 3D designs from any 3D printable material (metals, ceramics, and polymers). Locally tunable deformation and much higher elastic strains than the parent material would enable the next generation of compact, foldable and expandable structures. Mixing unit cells with different hinge angles, we designed gradient Poisson's ratio materials, as well as ones with multiple stable states where elastic energy can be stored in latching structures, offering prospects for multi-functional designs. Much like the energy efficient Venus flytrap, such structures can store elastic energy and release it on demand when appropriate stimuli are present.

On the application of additive manufacturing methods for auxetic structures: a review

“…An S-hinged unit cell design, as shown in Fig. 8 was proposed by Khare et al [143]. The design derives its inspiration from the common re-entrant cell design, which permits an easier tuneability and stability of the unit cells along with lower fatigue damage.…”

“…The structures exhibit a uniform elastic behavior in all principal directions while Fig. 8 Unit cell structure of an S-hinged unit cell [143] Fig. 9 Double-V unit cell structure [144] Fig.…”

Design of Shape Reconfigurable, Highly Stretchable Honeycomb Lattice With Tunable Poisson’s Ratio

“…Lattice structures can exhibit unusual properties by rationally arranging or adjusting their microstructures (Bertoldi et al, 2017). Among them, tunable Poisson's ratio is of particular interest (Fozdar et al, 2011;Ai and Gao 2017;Chen et al, 2017;Khare et al, 2018;Liu and Zhang. 2018;de Jongeet al, 2019).…”

Additively manufactured AlSi10Mg inherently stable thin and thick-walled lattice with negative Poisson’s ratio

“…Other significant architectures include the anti-chiral structures studied by Alderson et al [66] along with Pozniak and Wojciechowski [67] in addition to shape-preserving structures [68,69], and various composites [70,71]. Despite this, Zadpoor [72] found that studies in metals have been limited to beam-based architecture [73][74][75][76] with much less information on plate/sheet/walled/surface − architecture.…”