Digital synthesis of free-form multimaterial structures for realization of arbitrary programmed mechanical responses

SignificanceCreating structures to realize function-oriented mechanical responses is desired for many applications. Yet, the use of a single material phase and heuristics-based designs may fail to attain specific target behaviors. Here, through a deterministic algorithmic procedure, multiple materials with dissimilar properties are intelligently synthesized into composite structures to achieve arbitrary prescribed responses. Created structures possess unconventional geometry and seamless integration of multiple materials. Despite geometric complexity and varied material phases, these structures are fabricated by multimaterial manufacturing, and tested to demonstrate that wide-ranging nonlinear responses are physically and accurately realized. Upon heteroassembly, resulting structures provide architectures that exhibit highly complex yet navigable responses. The proposed strategy can benefit the design of function-oriented nonlinear mechanical devices, such as actuators and energy absorbers.