Engineering multi-layered bio-inspired deep-sea sponge lattices for enhanced mechanical performance via additive manufacturing

Euplectella aspergillum, a naturally occurring deep-sea sponge, possesses a skeletal architecture that uniquely combines mechanical robustness with outstanding energy, sound, and thermal absorption capabilities. Its geometry offers extraordinary promise as an inspiration for engineering design and shows tremendous scope for further enhancement in its mechanical and energy absorption properties. This study harnesses its architecture to develop novel multi-layered lattice structures, fabricated through material extrusion additive manufacturing, and systematically investigates their compressive and flexural performance. These newly developed multi-layered lattices demonstrated a 50% enhancement in Young’s modulus, a 138% increase in compressive strength, and nearly double (96%) the specific energy absorption compared to conventional lattices of identical density and weight. Ashby plots further reveal that these lattices achieve the highest SEA among all studied layered architectures, including those at higher densities—a testament to the efficiency of the sponge-inspired layering strategy. These findings establish a new paradigm for tailoring mechanical performance in bio-inspired structures with layering strategies. This work lays a strong foundation for the future development of high-performance, multifunctional lattices and sandwich lattice cores with applications across aerospace, defense, energy absorption systems, and beyond.