Performance Evaluation of Butterfly Shape‐Inspired Structures Produced via Additive Manufacturing Process

In this article, lattice structures inspired by the shape of butterfly wings are proposed. The butterfly wing‐inspired lattice structures (BFS) are 3D‐printed using thermoplastic polyurethane (TPU) material through the fused filament fabrication (FFF) technique. The parametric studies are conducted to investigate the effects of various factors, including strut thickness, unit cell size, loading direction, angles, and functional grading, on key properties, such as energy absorption, specific energy absorption, average plateau stress, and elastic modulus of the BFS structure. The performance of the BFS structure is compared with that of another bioinspired lattice, derived from the cross section of a seagull feather shaft (SFS), and it was found that the BFS structure exhibits superior energy absorption capacity. Furthermore, the BFS structure's performance is compared against other lattice structures previously discussed in the literature, revealing its higher energy absorption capacity. Additionally, the reusability of TPU‐based lattice structures is assessed through cyclic loading tests. The butterfly‐shaped lattice structure demonstrates continuous energy absorption even after complete failure, indicating its durability and effectiveness in energy dissipation. Due to its enhanced energy absorption capacity, the BFS structure holds promising potential for use in protective applications such as helmets, armor, and footwear insoles.