<p>Additive manufacturing (AM) has unlocked unprecedented opportunities for fabricating structurally complex materials. Inspired by natural materials such as bone and bamboo, a key frontier lies in hierarchical porous structures that offer both mechanical and functional benefits. This article discusses recent advances in multiscale AM approaches for the design and fabrication of hierarchical porous materials. From a design perspective, we examine lattice structures with self-similar and heterogeneous hierarchies, where repeating or dissimilar structural motifs extend across scales to optimize material performance. From a fabrication perspective, we discuss material-based approaches embedding hierarchical porosity through tailored formulations, alongside process-based approaches that expand the capabilities of AM platforms. Together, they significantly broaden the accessible design space for hierarchical porous materials in structural, acoustic, biomedical, and multifunctional applications. By presenting a unified framework integrating design and fabrication in multiscale AM, this article highlights the bioinspired principles, characteristic structures, and enhanced properties enabled by hierarchical designs.</p> Graphical abstract <p></p>

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Multiscale additive manufacturing of hierarchical porous materials

  • Quyang Liu,
  • Junhao Ding,
  • Xu Song,
  • Wei Zhai

摘要

Additive manufacturing (AM) has unlocked unprecedented opportunities for fabricating structurally complex materials. Inspired by natural materials such as bone and bamboo, a key frontier lies in hierarchical porous structures that offer both mechanical and functional benefits. This article discusses recent advances in multiscale AM approaches for the design and fabrication of hierarchical porous materials. From a design perspective, we examine lattice structures with self-similar and heterogeneous hierarchies, where repeating or dissimilar structural motifs extend across scales to optimize material performance. From a fabrication perspective, we discuss material-based approaches embedding hierarchical porosity through tailored formulations, alongside process-based approaches that expand the capabilities of AM platforms. Together, they significantly broaden the accessible design space for hierarchical porous materials in structural, acoustic, biomedical, and multifunctional applications. By presenting a unified framework integrating design and fabrication in multiscale AM, this article highlights the bioinspired principles, characteristic structures, and enhanced properties enabled by hierarchical designs.

Graphical abstract