Bioinspired energy absorbing material designs using additive manufacturing

Superlative mechanical energy absorbing efficiency discovered through self-driving lab-human partnership

Energy absorbing efficiency is a key determinant of a structure's ability to provide mechanical protection and is defined by the amount of energy that can be absorbed prior to stresses increasing to a level that damages the system to be protected. Here, we explore the energy absorbing efficiency of additively manufactured polymer structures by using a self-driving lab (SDL) to perform >25,000 physical experiments on generalized cylindrical shells. We use a human-SDL collaborative approach where experiments are selected from over trillions of candidates in an 11-dimensional parameter space using Bayesian optimization and then automatically performed while the human team monitors progress to periodically modify aspects of the system. The result of this human-SDL campaign is the discovery of a structure with a 75.2% energy absorbing efficiency and a library of experimental data that reveals transferable principles for designing tough structures.

Influence of Extruded Tubing and Foam-Filler Material Pairing on the Energy Absorption of Composite AA6061/PVC Structures

There is accelerating demand for energy-absorbing structures fabricated from lightweight materials with idealized, near-constant force responses to simultaneously resolve the engineering challenges of vehicle mass reduction and improved occupant safety. A novel compounded energy dissipation system composed of AA6061-T6 and AA6061-T4 tubing subjected to hybrid cutting/clamping and H130, H200 and H250 PVC foam compression was investigated utilizing quasi-static experiments, finite element simulations and theoretical modeling. Identical structures were also subjected to axial crushing to compare with the current state of the art. The novel cutting/foam crushing system exhibited highly stable collapse mechanisms that were uniquely insensitive to the tube/foam material configuration, despite the disparate material properties, and exceeded the energy-absorbing capacity and compressive force efficiency of the axial crushing mode by 14% and 44%, respectively. The simulated deformation profiles and force responses were consistent with the experiments and were predicted with an average error of 12.4%. The validated analytical models identified numerous geometric/material configurations with superior performance for the compounded AA6061/PVC foam cutting/foam crushing system compared to axial crushing. An Ashby plot comparing the newly obtained results to several findings from the open literature highlighted the potential for the compounded cutting/foam crushing system to significantly outperform several alternative lightweight safety systems.

Structure-property relationships of velar bone tissue from the energy absorbing horncore of bighorn sheep rams

Velar bone is the material that fills the horncore of bighorn sheep rams. The architectural dimensions of velar bone are orders of magnitude larger than trabecular bone, and velae are more sail-like compared to strut-like trabeculae. Velar bone is important for energy absorption and reduction of brain cavity accelerations during high energy head impacts, but velar bone material properties were previously unknown. It was hypothesized that velar bone tissue would have properties that are beneficial for increased energy absorption at the material level. Solid velar bone beams were tested using dynamic mechanical analysis and three-point bending to quantify mechanical properties. Additionally, the porosity, osteon population density, and mineral content of the solid velar sails were quantified. The velar bone damping factor (∼0.03 - 0.06) and modulus of toughness (3.9 ± 0.4 MJ/m3) were lower than other mammalian cortical bone tissues. The solid bony sails have a bending modulus (8.6 ± 0.5 GPa) that lies within the range of bending moduli values previously reported for individual trabecular struts and cortical bone tissue. The solid velar bone sails had porosity (6.7 ± 0.9 %) and bone mineral content (66 ± 1 %) in the range of cortical bone values. Interestingly, velar sails contained osteons, which are rarely found in trabecular struts. The velar bone osteon population density (5.8 ± 0.9 osteons/mm2) is in the low end of the range of values reported for cortical bone in other mammals. STATEMENT OF SIGNIFICANCE: Bighorn sheep rams sustain high energy head impacts during intraspecific combat without overt signs of brain injury. Previous studies have shown that the bony horncore plays a critical role in energy absorption and reduction of brain cavity accelerations post impact, which has implications for concussion prevention in humans. However, the material properties of the horncore velar bone were previously unknown. This study quantified the material properties and structure-property relationships of the horncore velar bone at the tissue level. Results from this study will improve our understanding of how bighorn sheep mitigate brain injury during head-to-head impacts and may inspire the design of novel materials for energy absorption applications (i.e., helmets materials that reduce concussion occurrence in humans).

Research Progress in Preparation, Properties and Applications of Biomimetic Organic-Inorganic Composites with "Brick-and-Mortar" Structure

Inspired by nature, materials scientists have been exploring and designing various biomimetic materials. Among them, composite materials with brick-and-mortar-like structure synthesized from organic and inorganic materials (BMOIs) have attracted increasing attention from scholars. These materials have the advantages of high strength, excellent flame retardancy, and good designability, which can meet the requirements of various fields for materials and have extremely high research value. Despite the increasing interest in and applications of this type of structural material, there is still a dearth of comprehensive reviews, leaving the scientific community with a limited understanding of its properties and applications. In this paper, we review the preparation, interface interaction, and research progress of BMOIs, and propose possible future development directions for this class of materials.

Research on biomimetic design and impact characteristics of periodic multilayer helical structures

Osteons are composed of concentric lamellar structure, the concentric lamellae are composed of periodic thin and thick sub-lamellae, and every 5 sub-lamellae is a cycle, the periodic helix angle of mineralized collagen fibers in two adjacent sub-lamellae is 30°. Four biomimetic models with different fiber helix angles were established and fabricated according to the micro-nano structure of osteon. The effects of the fiber periodic helical structure on impact characteristic and energy dissipation of multi-layer biomimetic composite were investigated. The calculation results indicated that the stress distribution, contact characteristics and fiber failur during impact, and energy dissipation of the composite are affected by the fiber helix angle. The stress concentration of composite materials under external impact can be effectively improved by adjusting the fiber helix angle when the material composition and material performance parameters are same. Compared with the sample30, the maximum stress of sample60 and sample90 increases by 38.1% and 69.8%, respectively. And the fiber failure analysis results shown that the model with a fiber helix angle of 30° has a better resist impact damage. The drop-weight test results shown that the impact damage area of the specimen with 30° helix angle is smallest among the four types of biomimetic specimens. The periodic helical structure of mineralized collagen fibers in osteon can effectively improve the impact resistance of cortical bone. The research results can provide useful guidance for the design and manufacture of high-performance, impact-resistant biomimetic composite materials.

Biomimicking Nature-Inspired Design Structures-An Experimental and Simulation Approach Using Additive Manufacturing

Whether it is a plant- or animal-based bio-inspiration design, it has always been able to address one or more product/component optimisation issues. Today's scientists or engineers look to nature for an optimal, economically viable, long-term solution. Similarly, a proposal is made in this current work to use seven different bio-inspired structures for automotive impact resistance. All seven of these structures are derived from plant and animal species and are intended to be tested for compressive loading to achieve load-bearing capacity. The work may even cater to optimisation techniques to solve the real-time problem using algorithm-based generative shape designs built using CATIA V6 in unit dimension. The samples were optimised with Rhino 7 software and then simulated with ANSYS workbench. To carry out the comparative study, an experimental work of bioprinting in fused deposition modelling (3D printing) was carried out. The goal is to compare the results across all formats and choose the best-performing concept. The results were obtained for compressive load, flexural load, and fatigue load conditions, particularly the number of life cycles, safety factor, damage tolerance, and bi-axiality indicator. When compared to previous research, the results are in good agreement. Because of their multifunctional properties combining soft and high stiffness and lightweight properties of novel materials, novel materials have many potential applications in the medical, aerospace, and automotive sectors.

Bionic design based on micro-nano structure of osteon and its low-velocity impact damage behavior

It is found that the osteon is composed of thin and thick lamellae which are periodic and approximately concentric, every 5 lamellae is a cycle, the periodic helix angle of mineralized collagen fibers in two adjacent sub-lamellae is 30°. Four bionic composite models with different fiber helix angles were established and fabricated according to the microstructure of mineralized collagen fibers in osteon. Based on the impact analysis of four kinds of bionic composite models, the effects of the fiber periodic spiral structure on the impact resistance and energy dissipation of multi-layer bionic composite were investigated. The analysis results show that the fiber helix angle affects the impact damage resistance and energy dissipation of multi-layer fiber reinforced composites. Among the 4 kinds of multi-layer composite models, the composite model with helix angle of 30° has better comprehensive ability to resist impact damage. The test results show that the impact damage area of the specimen with 30° helix angle is smallest among the 4 types of bionic specimens, which is consistent with the results of finite-element impact analysis. Furthermore, in the case of without impact damage, the smaller the fiber helix angle is, the more uniform the stress distribution is and more energy is dissipated in the impact process. The periodic spiral structure of mineralized collagen fibers in osteon are the result of natural selection of biological evolution. This structure can effectively improve the ability of cortical bone to resist external impact. The research results can provide useful guidance for the design and manufacture of high-performance and strong impact resistant bionic composites.

Evaluation of the Orthotropic Behavior in an Auxetic Structure Based on a Novel Design Parameter of a Square Cell with Re-Entrant Struts

In this research, a three-dimensional auxetic configuration based on a known re-entrant cell is proposed. The 3D auxetic cell is configured from a new design parameter that produces an internal rotation angle to its re-entrant elements to study elastic properties in its three orthogonal directions. Through a topological analysis using Timoshenko beam theory, the bending of its re-entrant struts is modeled as a function of the new design parameter to manipulate Poisson's ratio and Young's modulus. Experimental samples were fabricated using a fused filament fabrication system using ABS and subsequently tested under quasi-static compression and bending tests. Additionally, an orthotropy factor is applied that allows for measuring the deviation between the mechanical properties of each structure. The experimental results validate the theoretical design and show that this new unit cell can transmit an orthotropic mechanical behavior to the macrostructure. In addition, the proposed structure can provide a different bending stiffness behavior in up to three working directions, which allows the application under different conditions of external forces, such as a prosthetic ankle.

The Study of Mechanical Behaviors of Caprinae Horn Sheath under Pendulum Impact

As a light-weight natural keratin biocomposite, Bovidae horn exhibits high mechanical properties and energy absorption. Different to the widely studied horn from subfamily Bovinae and Antilocapridae, few studies have focused on the horn sheath of subfamily Caprinae. In this work, three Caprinae horn sheathes from Cashmere goat, White goat and Black sheep were selected. Charpy pendulum impact tests were performed, and the fracture characteristics were evaluated. It was demonstrated that water plays an important role in acquiring balanced dynamic mechanical properties in all Caprinae horn sheaths. The hydrated keratin provides large plastic deformation capacity and further gives rise to a gradual generation of micro-cracks. Multi-scale structure including wavy-shaped interface, scattered voids and hierarchical micro-fibre were observed. Such a structure induced complex fracture mechanisms, such as delamination, 90° crack deflection and fibre pull-out, which were probably influenced by interfacial strength. The results are expected to endow the research and thinking of Bovidae horn.

Unravelling the structural variation of lizard osteoderms

Vertebrate skin is a remarkable organ that supports and protects the body. It consists of two layers, the epidermis and the underlying dermis. In some tetrapods, the dermis includes mineralised organs known as osteoderms (OD). Lizards, with over 7,000 species, show the greatest diversity in OD morphology and distribution, yet we barely understand what drives this diversity. This multiscale analysis of five species of lizards, whose lineages diverged ∼100-150 million years ago, compared the micro- and macrostructure, material properties, and bending rigidity of their ODs, and examined the underlying bones of the skull roof and jaw (including teeth when possible). Unsurprisingly, OD shape, taken alone, impacts bending rigidity, with the ODs of Corucia zebrata being most flexible and those of Timon lepidus being most rigid. Macroscopic variation is also reflected in microstructural diversity, with differences in tissue composition and arrangement. However, the properties of the core bony tissues, in both ODs and cranial bones, were found to be similar across taxa, although the hard, capping tissue on the ODs of Heloderma and Pseudopus had material properties similar to those of tooth enamel. The results offer evidence on the functional adaptations of cranial ODs, but questions remain regarding the factors driving their diversity. STATEMENT OF SIGNIFICANCE: Understanding nature has always been a significant source of inspiration for various areas of the physical and biological sciences. Here we unravelled a novel biomineralization, i.e. calcified tissue, OD, forming within the skin of lizards which show significant diversity across the group. A range of techniques were used to provide an insight into these exceptionally diverse natural structures, in an integrated, whole system fashion. Our results offer some suggestions into the functional and biomechanical adaptations of OD and their hierarchical structure. This knowledge can provide a potential source of inspiration for biomimetic and bioinspired designs, applicable to the manufacturing of light-weight, damage-tolerant and multifunctional materials for areas such as tissue engineering.

Biomineralized Materials as Model Systems for Structural Composites: 3D Architecture

Biomineralized materials are sophisticated material systems with hierarchical 3D material architectures, which are broadly used as model systems for fundamental mechanical, materials science, and biomimetic studies. The current knowledge of the structure of biological materials is mainly based on 2D imaging, which often impedes comprehensive and accurate understanding of the materials' intricate 3D microstructure and consequently their mechanics, functions, and bioinspired designs. The development of 3D techniques such as tomography, additive manufacturing, and 4D testing has opened pathways to study biological materials fully in 3D. This review discusses how applying 3D techniques can provide new insights into biomineralized materials that are either well known or possess complex microstructures that are challenging to understand in the 2D framework. The diverse structures of biomineralized materials are characterized based on four universal structural motifs. Nacre is selected as an example to demonstrate how the progression of knowledge from 2D to 3D can bring substantial improvements to understanding the growth mechanism, biomechanics, and bioinspired designs. State-of-the-art multiscale 3D tomographic techniques are discussed with a focus on their integration with 3D geometric quantification, 4D in situ experiments, and multiscale modeling. Outlook is given on the emerging approaches to investigate the synthesis-structure-function-biomimetics relationship.

Lizard osteoderms - Morphological characterisation, biomimetic design and manufacturing based on three species

Osteoderms (OD) are mineralised dermal structures consisting mainly of calcium phosphate and collagen. The sheer diversity of OD morphologies and their distribution within the skin of lizards makes these reptiles an ideal group in which to study ODs. Nonetheless, our understanding of the structure, development, and function of lizard ODs remains limited. The specific aims of this study were: (1) to carry out a detailed morphological characterisation of ODs in three lizard species; (2) to design and manufacture biomimetic sheets of ODs corresponding to the OD arrangement in each species; and (3) to evaluate the impact resistance of the manufactured biomimetic sheets under a drop weight test. Skin samples of the anguimorphsH. suspectumandO. ventralis, and the skinkC. zebratawere obtained from frozen lab specimens. Following a series of imaging and image characterisations, 3D biomimetic models of the ODs were developed. 3D models were then printed using additive manufacturing techniques and subjected to drop weight impact tests. The results suggest that a 3D printed compound of overlapping ODs as observed inCoruciacan potentially offers a higher energy absorption by comparison with the overlapping ODs ofOphisaurusand the non-overlapping ODs ofHeloderma.Compound overlapping ODs need to be further tested and explored as a biomimetic concept to increase the shock absorption capabilities of devices and structures.