Intertwined microlattices greatly enhance the performance of mechanical metamaterials

Mechanical metamaterials demonstrate augmented properties derived from their engineered structure. Advances in three-dimensional (3D) printing technologies have enabled the fabrication of complex metamaterial structures even at the microscale, contributing to the development of light-weight materials with superior mechanical properties. However, understanding of metamaterial strain hardening that is intrinsic to both the structure and arrangement of novel unit cells is sparse and fairly empirical. The main objective of this study was to introduce a new design approach for 3D mechanical metamaterials with enhanced strain hardening and energy absorption, fabricated at the microscale by multiphoton lithography, which is the only fabrication technique that can produce micrometer length scales and high structural complexity. This was accomplished by intertwining simple polyhedra to create more complex geometries in 3D space, using penetration twins as a point of reference, a mechanism of crystal in-growth wherein distinct crystals appear to penetrate each other. This structural principle was used to intertwine the lattice members of the structure and tailor their buckling behavior. The present design is inspired by the first stellation of the rhombic dodecahedron. With this concept, plastic deformation can be controlled through localized buckling of select lattice members. Finite element simulations and nanoindentation experiments demonstrate remarkably improved performance with respect to both strain hardening and energy dissipation of the structure compared to both the bulk material and one of the most thoroughly studied ultralight, ultrastiff mechanical metamaterials, the octet truss.