Micro-scale truss structures with three-fold and six-fold symmetry formed from self-propagating polymer waveguides

A process for interconnecting a three-dimensional pattern of self-propagating polymer waveguides was used to form micro-truss structures with two new unit cell architectures. The structures were formed using a two-dimensional mask with a hexagonal pattern of apertures. Distinct unit cell architectures were possible by exposing the mask to a different number of incident UV exposure beams, which are used to form the waveguides. One unit cell design featured three intersecting waveguides per node, resulting in a structure with three-fold symmetry. The second unit cell design had six-fold symmetry and was characterized by primary nodes with six intersecting waveguides and secondary nodes with two intersecting waveguides. Compression loading experiments were conducted on micro-truss samples with comparable relative density values (ρ/ρs = 6.5%), but different unit cell architectures. The addition of secondary nodes in the structures based on the second design led to an increase in compressive modulus of up to 70% and an average increase in peak strength of 42%. The increase in compressive strength and modulus was attributed to a reduction in the truss-member slenderness ratio achieved through increased waveguide connectivity.