Mechanically and electromagnetically tuned lattice structures via additive manufacturing: a dual-functional design approach using PLA


Mahouti T., Belen M. A., YILMAZER H.

Smart Materials and Structures, cilt.35, sa.4, 2026 (SCI-Expanded, Scopus) identifier identifier

  • Yayın Türü: Makale / Tam Makale
  • Cilt numarası: 35 Sayı: 4
  • Basım Tarihi: 2026
  • Doi Numarası: 10.1088/1361-665x/ae5ffa
  • Dergi Adı: Smart Materials and Structures
  • Derginin Tarandığı İndeksler: Science Citation Index Expanded (SCI-EXPANDED), Scopus, Compendex, INSPEC
  • Anahtar Kelimeler: additive manufacturing, antenna integration, electromagnetic performance, lattice structures, mechanical properties
  • Yıldız Teknik Üniversitesi Adresli: Evet

Özet

Lattice structures are promising for lightweight biomedical implants due to high strength to weight ratios and porous architectures that mimic bone. In this study, the effects of pore size, porosity, wall thickness, and unit cell geometry on the mechanical and electromagnetic (EM) performance of polylactic acid lattice scaffolds fabricated via fused deposition modeling are systematically investigated. Using a Taguchi L9 design, nine lattice variants were fabricated: hexahedron (H-series), gyroid (G-series), rhombicuboctahedron (R-series) geometries with pore sizes of 200–600 µm and wall thickness of 300–500 µm. Compression tests and finite element analysis were performed to identify optimal designs. The hexahedron geometry achieved the highest fidelity to the computer aided design and superior compressive strength, with sample H36 (500 µm pore, 300 µm wall) exhibiting an elastic modulus of ∼530 MPa and yield strength ∼14 MPa, closest to the range of trabecular bone. Only the most porous gyroid and rhombic samples fell below the 100 MPa elastic modulus threshold for bone applications. Building on these results, the optimized H36 lattice was repurposed as a dielectric substrate for a microstrip antenna. Both simulation and experiment confirmed a resonance at 6.6 GHz with a minimum S₁₁ of −17.4 dB and a broad ∼3.2 dBi gain pattern, demonstrating effective EM operation without loss of mechanical integrity. This dual functionality combining structural support and wireless capability introduces a new direction for smart lattice implants and sensor integrated lightweight components.