The design‐manufacturing‐evaluation integration of a bionic stealth metastructure inspired by the weevils back shell structure

Abstract With the advancement of technology, the demand for high‐performance stealth materials with complex structures has increased significantly. This study explores the integration of design, manufacturing, and evaluation of stealth structures using fused deposition modeling (FDM) combined with advanced absorbing materials. Focusing on nylon‐based filaments optimized for broadband absorption, the research is inspired by the microstructure of the weaver ant's back shell to create a thin‐layer, wideband absorbing structure with wide‐angle response, employing the trust region algorithm. This integration of high dielectric loss materials, bionic design, and FDM technology enhances manufacturing efficiency and reduces the structure's thickness. The resulting structure achieves broadband absorption from 3.56 to 40 GHz, excellent angular adaptability, and mechanical robustness. Compared to gradient cell structures, it reduces thickness by 33% and extends the absorption frequency range by 5%. This approach offers a lightweight, high‐performance solution for next‐generation stealth applications. Highlights Biomimetic inspired design‐manufacturing‐evaluation integration. Trust domain algorithm optimization. Improve absorption by combining the macro structure and micro materials. Additive manufacturing cross‐enabled functional material design.