Design and Evaluation of the Mechanical Performance of Hollow BCC Truss AlSi10Mg Lattice Structures

Lattice materials demonstrate exceptional advantages in lightweight design applications due to their low mass density, high specific strength, and customizable topology. Inspired by the hollow vascular bundle structure of bamboo, this study develops four bio-inspired lattice configurations through two key modifications to conventional body-centered cubic (BCC) structures: Z-axis (loading direction) strut reinforcement and strut hollowing. The specimens were fabricated using AlSi10Mg powder via selective laser melting (SLM) technology, followed by the systematic evaluation of the compressive properties and the energy absorption characteristics. The experimental results reveal that the synergistic combination of Z-strut reinforcement and hollow design significantly enhances both the compressive resistance and the energy absorption capacity. The optimized BCC-5ZH configuration (5 Z-struts with full hollowing) achieves remarkable performance metrics at 0.5 g/cm3 density: yield strength (16.78 MPa), compressive strength (27.91 MPa), and volumetric energy absorption (10.4 MJ/m3). These values represent 236.9%, 283.4%, and 239.3% enhancements, respectively, compared to the reference BCC lattices with an equivalent density. Z-strut integration induces homogeneous stiffness distribution throughout the lattice architecture, while strut hollowing increases the effective moment of inertia. This structural evolution induces a failure mode transition from single shear band deformation to dual X-shaped shear band propagation, resulting in enhanced deformation sequence regulation within the lattice system.