Digital Image Correlation and Numerical Analysis of Mechanical Behavior in Photopolymer Resin Lattice Structures

Cellular structures are increasingly utilized in modern engineering due to their exceptional mechanical and physical properties. In this study, the deformation and failure mechanisms of two energy-efficient lattice structures-hexagonal honeycomb and re-entrant honeycomb-were investigated. These structures were manufactured using additive stereolithography with light-curable Durable Resin V2. The experimental testing of the topologies under two perpendicular loading directions employed the 3D Digital Image Correlation (DIC) system to capture strain fields and deformation patterns, providing insights into structural behavior and failure mechanisms. The unit cells of the topologies were scaled up to enable precise optical measurements while preserving their structural interaction characteristics. Numerical simulations, conducted using the SAMP-1 material model in LS-DYNA and calibrated with tensile and compression test data, accurately replicated the behavior of the studied topologies and demonstrated good agreement with experimental results. The hexagonal structure, loaded along axis 2, showed the best fit, with deviations within 5%, while the re-entrant honeycomb structure exhibited weaker yet reasonable agreement. By integrating experimental and numerical approaches, the research validates the SAMP-1 model's predictive capabilities for lattice structures and provides a framework for analyzing energy-absorbing lattice topologies.