Design strategies for enhancement of mechanical behaviour of hybrid cellular structures based on schwarz primitive geometry

Hybrid cellular structures are gaining attention for their multi-functionality in load-bearing, heat-transfer, and energy-absorption applications. Schwarz Primitive(SCP)-based geometries, a subclass of Triply Periodic Minimal Surfaces (TPMS), with their high surface area, tunable properties, and continuous topology, provide strong potential for such applications. To further enhance mechanical performance and stability, this work conducts a thorough investigation of hybrid designs that integrate SCP TPMS with Kelvin truss-based geometries, combining the high connectivity of TPMS with the reinforcement and directional stiffness benefits of struts. A theoretical strain-based homogenization framework was implemented over a design matrix that independently varies the relative densities of the SCP and the truss geometries, quantifying how each constituent proportion influences the overall mechanical response of the hybrid. These predictions were corroborated by finite element analyses in ANSYS 2023 and by mechanical testing of 3D-printed polylactic acid samples, providing independent validation of homogenization trends across orientations. The resulting formulation enables rapid property mapping, sensitivity analysis, and optimization of SCP-Kelvin hybrids, thereby reducing the prototyping effort while guiding application-based design selection and customization. • Hybrid topologies combine different lattice types for tailored strength and stiffness. • Structures are studied using experiments, simulations, and simple predictive models. • Smaller cell sizes exhibit higher stiffness due to more uniform stress distribution. • Constrained polynomial fitting provides accurate stiffness predictions. • Fitting method enables rapid prototyping and fast screening of new designs. • Combined approach supports design of strong, lightweight lattice materials.