Mechanical and microstructural investigation of novel bio-inspired DNA and hybrid lattices

Additive manufacturing is transforming structural design for industrial applications by enabling the fabrication of complex, biologically inspired geometries with high precision. This approach enhances mechanical performance by maximizing strength and minimizing weight, paving the way for next-generation lightweight, high-strength structures. This study investigates bioinspired designs based on natural elements such as DNA, the nautilus shell, and the basal body. Two structures, a DNA-based and a hybrid design were additively manufactured and analysed, incorporating variations in wall thickness (0.8 mm and 0.9 mm), DNA patterns (hexagonal and single), centriole-inspired tube angles (35° and 40°), and three curvature configurations in the nautilus structure. Mechanical performance was evaluated through both numerical simulations and experimental testing, and results were compared with earlier designs (centriole, nautilus, and hybrid). The hexagonal DNA structure posed manufacturability challenges due to its intricate fine links. However, components produced via the Vat Photopolymerization process exhibited excellent strength-to-weight ratios, combining lightweight properties with structural integrity. Compressive strength and failure mechanisms were also analysed, showing superior stiffness and energy absorption. Remarkably, the DNA and hybrid structures matched the strength of conventional designs while reducing material usage by approximately 45% and 25%, respectively. Additionally, microstructural analysis of the fractured surfaces provided insight into failure modes and post-deformation material behaviour.