High-performance programmable combinatorial lattice materials

Abstract

A long-standing challenge in modern materials design is overcoming inefficient and arbitrary trial-and-error approaches. To tackle this challenge, this study introduces a novel concept of “combinatorial lattices” and establishes a comprehensive performance library to enable systematic, property-driven design. Through a combination of theoretical modeling, finite element simulations, and experimental validation, this study demonstrates the effectiveness of this approach in facilitating both anisotropic design and tradeoff design across multiple mechanical properties. The resulting combinatorial lattices achieve stiffness and strength values up to 66.0 % of the Hashin–Shtrikman upper bound and 60.2 % of the Suquet bound, respectively. Notably, the combinatorial lattices exhibit relative strengths approaching—or even exceeding—the empirical upper bounds predicted by the Gibson-Ashby model. The energy absorption per unit volume surpasses that of comparable-density lattices by more than threefold, and the CFE reaches a remarkable 151 %. Beyond superior static performance, the Kelvin+BCC lattice demonstrates exceptional damage tolerance under 5 cyclic loading, retaining 99.5 % of its initial strength and 79.9 % of its initial stiffness after repeated compression at high strain levels. This work provides a programmable mechanomaterial design framework that proactively integrates geometric combinatorics with performance-driven criteria, offering a robust pathway for the development of high-performance lattice structures and advanced materials.