Mechanism-Driven Design and Validation of a Multi-Material Polymeric Auxetic for Deformation-Activated Sealing

Auxetic polymers offer a route to deformation-activated sealing by transforming axial deformation into lateral expansion, enabling controlled conformity and retention within perforated structures. This paper presents the design-space-guided optimisation of a multi-material polymeric auxetic plug for mechanically activated sealing of circular perforation surrogates relevant to military ground-vehicle structures using a controlled thin-wall surrogate validation framework. The sealing combines an SLA-printed Elastic 50A photopolymer auxetic body with TPU 95A load-transfer and priming components. A parameterised re-entrant unit cell was optimised using response-surface design of experiments coupled with nonlinear finite-element analysis. The optimised geometry, with a height of 6 mm, length of 5 mm, strut thickness of 1.25 mm, and re-entrant angle of 31°, achieved a predicted negative Poisson’s ratio of −2.66 under 20% axial strain. Experimental validation using additively manufactured unit cells confirmed the intended auxetic deformation response. The optimised structure was then integrated into a multi-material plug and tested against a solid polymer benchmark, achieving sealing to approximately 22 kPa with improved anchoring across the tested 22–25 mm perforation range. The results establish a mechanism-driven pathway from polymer auxetic unit-cell optimisation to plug-level pressure-sealing performance, demonstrating the potential of multi-material auxetic architectures as deformation-activated sealing systems for temporary repair of perforated military ground-vehicle structures.