Synergistic Enhancement of 3D Printed Lattices' Mechanical Performance and Energy Absorption via Integration of Stochastic Foam

ABSTRACT Lightweight lattice structures have gained attention in engineering applications for their high strength‐to‐weight ratio, tuneable mechanical properties, and energy absorption potential. This study explores an innovative approach to produce lightweight, stiff, and strong 3D‐printed lattice structures with enhanced energy absorption via foam integration. The work examines three lattice geometries: a triply periodic minimal surface (TPMS) based on the Schwarz diamond design, a perforated plate lattice (PLS), and a truss‐based octet lattice (TLS). Each is produced at three relative densities to evaluate the effect of density on mechanical performance. The mechanical behavior of these lattices under compression is examined when empty and when fully foam‐filled. The fused filament fabrication (FFF) 3D printing technique is used. This experimental investigation assesses the impact of foam infill on the stiffness, strength, and energy absorption capacity of the structures. Results are analyzed using Ashby criteria for lightweight structural materials to benchmark mechanical performance. This work highlights the potential of foam‐filled lattices for developing lightweight structures with enhanced compressive performance. It offers insights into how the foam provides lateral support to lattice cell walls, which suppresses premature buckling, thereby enhancing stiffness and energy absorption.