A Novel Dual Curved Cubic (DCC) structure with improved compressive strength

Lattice structures are valuable in engineering applications due to their high strength-to-weight ratios and excellent energy absorption capabilities. Their use has expanded considerably with advancements in additive manufacturing, enabling the production of complex designs. This study investigates a novel lattice structure inspired by “inosculation” phenomenon, a natural grafting process in plants and trees. The resulting lattice structure, termed Dual Curved Cubic (DCC), was represented via a Matlab-based implicit modeling algorithm for defining curved strut lattices. Test specimens of the DCC structure at 25% relative density and 70° curvature angle were fabricated with photo-sensitive resin in a vat photopolymerization apparatus and subjected to quasi-static compressive tests. The numerical and experimental results for the DCC were then compared with conventional structures, Body-Centered Cubic (BCC) and Octet lattices, to evaluate the relative yield strength, elastic modulus, and energy absorption properties. The DCC demonstrated a superior compressive strength of 4.53 MPa, exceeding that of the Octet (3.17 MPa) and BCC (2.28 MPa) lattice structures at the same relative density. The energy absorption of the DCC (42.61%) was observed to be lower than those of both Octet (68.86%) and BCC (64%) at the investigated curvature angle and relative density. However, by reducing the curvature and density, a significant improvement in energy absorption was observed, making these geometric parameters useful controls for optimizing mechanical performance. • A novel Dual Curved Cubic (DCC) cell inspired by the inosculation in trees was developed. • Potentially the first study on modelling curved strut lattices using signed distance functions. • A 70°DCC structure showed a higher compressive strength than BCC and Octet cells. • A Gibson–Ashby model predicts yield strength and elastic modulus vs relative density.