Tuning biomimetic open-cell foam structure: a promising way to tailor the mechanical behaviors of two-phase composite

Natural organisms have evolved diverse porous/foam architectures for optimal performance of two-phase composite. Inspired by these biological designs, this work develops a novel Voronoi-based modelling method for open-cell foams. The method regulates scaffold morphology through single geometry parameter, i.e. intercellular distance d, generating biomimetic geometries ranging from pomelo-peel-like to trabecular-bone-like structures. Using SiC_3D/Al composites as model materials, the geometry-property relationship is established by finite element analysis (FEA). For these foam-reinforced composites, larger SiC/Al interfaces enhance load transfer efficiency. Consequently, strength decreases monotonically (356 → 326 MPa) with increasing d due to reduced interface area. Extreme d values (low or high) cause sharp and concave features that trigger catastrophic SiC_3D fragmentation, reducing ductility. Peak elongation (3.98 %) occurs at d = 0.65. Thus, optimal performance requires d ≤ 0.65. Structural design alone cannot simultaneously maximize strength and toughness. The matrix-reinforcement compatibility is essential, demanding tough matrices and ultra-strong reinforcements.