Additive Manufacturing of Lightweight Buckling Resistant Bio-Inspired Lattice Cores

Advanced cellular structures, characterized by ordered or stochastic porous architectures, have emerged as potential solutions for strong and lightweight applications. However, at low relative densities (5–30%), such structures experience localized and global buckling of their slender features, limiting viability in load-bearing systems. To address this challenge, we leveraged a high-performing lattice designs from nature, that can sustain extreme hydrostatic pressures through its microscopic lamellar and asymmetric sinusoidal architecture. Inspired by the cuttlefish bone, we designed a simplified cuttlebone structure comprising S-shaped sinusoidal walls governed by an explicit mathematical function. A two-dimensional (2D) planar design was developed by extruding in the third dimension, while ensuring low relative density (6.7%) and adhering to manufacturing constraints. Cubic lattices (30, 45, and 60 mm global dimensions) with 2×2 unit cells cross-section were fabricated via stereolithography and tested under out-of-plane quasi-static compression loads. Compared to a traditional square honeycomb structure of similar mass and dimensions, the cuttlebone design exhibited superior buckling resistance at the 30 and 45 mm scales, sustaining loads up to 58,000 times its own weight while retaining stiffness. Furthermore, the biomimetic structure demonstrated stable deformation behavior, with gradual load escalation to buckling point, contrasting the intermediate stiffness loss observed in the traditional counterpart. This study underscores the potential of nature-driven design principles to overcome performance limitations in architected lattices. By emulating biological architectures like the cuttlebone, we demonstrate lightweight cellular cores with enhanced mechanical strength and stability.