A novel geometrically-reconstructed primitive-like lattice for additive manufacturing: Shape-Controlled elasticity and deformation mechanisms

Abstract

To overcome the efficiency limitations in additive manufacturing and structural analysis caused by the excessive mesh complexity of curved lattice structures, a novel geometrically-reconstructed Primitive-like lattice is proposed. This sheet-based parametric lattice integrates geometric simplification and surface planarization, significantly reducing STL file size and enhancing slicing efficiency. The mechanical behavior of the structure—including equivalent elastic modulus, shear modulus, elastic anisotropy, and deformation mechanisms—was systematically investigated through homogenization theory, finite element simulations, and quasi-static compression tests. Results show that shape parameters, compared to volume fraction, offer superior tunability of mechanical properties and enable elastic isotropy across a wide design space. Furthermore, the structure exhibits stable energy absorption under both uniaxial and shear loading, attributed to its uniform sheet thickness that suppresses stress drops from local lattice instabilities. Combining high specific stiffness with improved manufacturability, the proposed lattice offers a promising solution for lightweight, large-scale applications in aerospace and structural engineering.