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<p>Lattice structures manufactured via additive manufacturing (AM) technologies offer substantial potential for application-specific energy absorption solutions across automotive, aerospace, and medical sectors, yet systematic frameworks for translating performance requirements into manufacturable design parameters remain limited. This investigation examines the mechanical behavior and manufacturing repeatability of Face-Centered Cubic (FCC) and Diamond lattice architectures produced through binder jetting (BJ) technology of thermoplastic polyurethane (TPU) across four density levels, with comprehensive characterization of energy absorption performance and failure mechanisms. Uniaxial compression testing was conducted, with detailed analysis of deformation behavior, densification characteristics, and manufacturing consistency. The deformation evolution of the analyzed structures was captured by a digital camera and analyzed through Digital Image Correlation (DIC). Finite element model was also involved to better understand the stress and strain of different structures. Diamond lattice structures demonstrated superior energy absorption performance with 35–45% higher specific energy absorption capacity compared to equivalent-density FCC architectures, exhibiting progressive loading characteristics and extended useful deformation range beyond 60% strain. Manufacturing repeatability analysis revealed coefficient of variation values below 10% for Diamond structures across all mechanical properties, indicating process maturity suitable for mass customization applications. These results validate binder jetting technology for reliable production of customized lattice-based energy absorption components, providing a systematic framework for application-specific lightweight design across multiple industrial sectors.</p>

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Mechanical characterization for optimal design of wearable customized energy absorption structures made by TPU through binder jetting process

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2026年3月25日

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  • Francesco Lambiase,
  • Francesco Pace,
  • Elena Andreucci,
  • Alfonso Paoletti

摘要

Lattice structures manufactured via additive manufacturing (AM) technologies offer substantial potential for application-specific energy absorption solutions across automotive, aerospace, and medical sectors, yet systematic frameworks for translating performance requirements into manufacturable design parameters remain limited. This investigation examines the mechanical behavior and manufacturing repeatability of Face-Centered Cubic (FCC) and Diamond lattice architectures produced through binder jetting (BJ) technology of thermoplastic polyurethane (TPU) across four density levels, with comprehensive characterization of energy absorption performance and failure mechanisms. Uniaxial compression testing was conducted, with detailed analysis of deformation behavior, densification characteristics, and manufacturing consistency. The deformation evolution of the analyzed structures was captured by a digital camera and analyzed through Digital Image Correlation (DIC). Finite element model was also involved to better understand the stress and strain of different structures. Diamond lattice structures demonstrated superior energy absorption performance with 35–45% higher specific energy absorption capacity compared to equivalent-density FCC architectures, exhibiting progressive loading characteristics and extended useful deformation range beyond 60% strain. Manufacturing repeatability analysis revealed coefficient of variation values below 10% for Diamond structures across all mechanical properties, indicating process maturity suitable for mass customization applications. These results validate binder jetting technology for reliable production of customized lattice-based energy absorption components, providing a systematic framework for application-specific lightweight design across multiple industrial sectors.