Deformable cellular solid structures based on multi-material assemblage

Abstract The intrinsic coupling between a material’s modulus of elasticity and its bending stiffness often limits the ability of structural systems to achieve both high load-bearing capacity and desired flexibility. Altering stiffness solely through changes in material properties is frequently impractical. While lightweight microporous structures offer excellent out-of-plane load support, their rigidity restricts their adaptability in applications requiring deformation. In this study, we propose a design and manufacturing strategy for deformable cellular solid structures (DCSS) that achieve programmable bending behavior and high mechanical performance. This architecture decouples bending stiffness from the modulus of elasticity, enabling the structures to support loads exceeding 10⁶ times their own weight while maintaining exceptional flexibility. The mechanical response of the DCSS can be precisely controlled, allowing for customizable deformation behavior and elastic recovery. These structures also exhibit strong modularity and shape adaptability, making them well-suited for use in protective devices, soft robotics, and deployable systems.