Material extrusion of topologically engineered architecture inspired by carbon-based interlocked petal-schwarzites

• Developed a new class of porous structure named petal-schwarzites. • The mechanical response can be tuned by the number of interlocked layers. • The stress concentration region is mitigated using multi-layered petal-schwarzites. Exploiting the topologically engineered complex Schwarzite architecture has allowed the creation of innovative and distinctive structural elements possessing high specific strength. These fundamental building blocks' mechanical characteristics can be fine-tuned by reinforcing them with more robust architectures featuring high surface areas. In this work, we have fabricated six distinct Schwarzite-based structures composed of multiple interlocked layers, termed architecturally interlocked petal-schwarzites. These intricate structures have been additively manufactured into macroscopic dimensions and subjected to uniaxial compression. Experimental findings reveal a correlation between the mechanical response and the number of layers. Additionally, fully atomistic molecular dynamics compressive simulations have been carried out, yielding results that are in good agreement with the experimental observations. These simulations provide insights into the underlying mechanism of high specific strength and energy absorption exhibited by architecturally interlocked petal-schwarzites. The proposed methodology introduces a new perspective on the development of engineered additively manufactured materials with tunable and enhanced mechanical properties.