Enhancing Ceramic Structural and Interfacial Properties via Micro‐Patterning and Macro‐Architectural Integration

Abstract This study investigates a dual‐scale strategy combining micro‐patterning with macro‐architectural features to enhance the mechanical and interfacial properties of bioinspired ceramic composites. High‐tolerance alumina tiles are precisely laser‐micromachined with unidirectional (0°, 90°, and 45°) and bidirectional ((0°, 90°) and ±45°) patterns, then laminated with thermoplastic Surlyn layers through vacuum bagging and heat treatment to achieve optimal bonding. Double lap joint (DLJ) and three‐point bending (3PB) tests are performed to evaluate interfacial bonding, flexural behavior, and energy absorption. DLJ results indicated significant enhancement in interfacial bonding, with the ±45° pattern achieving a 107% increase in interfacial damage dissipation energy compared to plain specimens, attributed to mechanical interlocking and crack deflection. In 3PB tests, unidirectional patterns showed minimal impact on flexural properties, whereas bidirectional patterns reduced stiffness and strength. However, integrating micro‐patterns with hexagonal macro‐architectures notably improved energy absorption by 60% in laminated ceramic beams. This synergistic dual‐scale approach represents a substantial advancement over conventional ceramics, enabling superior post‐failure performance and energy absorption, with the potential for resilient materials in aerospace and other high‐performance applications.