Design and optimization of nature-inspired polygon-based lattice structures for lightweight and high-strength applications

Abstract Additive manufacturing stands at the cutting edge of modern production, enabling the fabrication of intricate geometries such as lattice structures with superior stiffness-to-weight ratios that are often unattainable through conventional methods. This study focuses on the development and evaluation of polygon-based lattice structures inspired by naturally occurring botanical forms, known for their efficient load distribution and structural connectivity. Square, triangular, and pentagonal unit cells were systematically designed across three porosity levels (50%, 55%, and 60%) to investigate the influence of geometry on mechanical performance. High-resolution stereolithography (SLA) 3D printing was employed to fabricate the samples, ensuring precision in capturing fine lattice details critical for accurate mechanical assessment. Finite Element Analysis (FEA) was employed to evaluate the mechanical performance of bio-inspired lattice structures under multidirectional compressive loading. The investigation integrated both computational simulations and experimental testing to validate structural behavior. Among the configurations studied, the pentagon geometry with 50% porosity lattice exhibited the best compressive performance, with a peak strength of 40.1 MPa, which is 62% higher than the 50% square lattice and 170% higher than the 60% triangle lattice. Additionally, Scanning Electron Microscopy (SEM) analysis was conducted to examine fracture mechanisms and microstructural integrity.