A Janus‐Like Bio‐Inspired Strategy for 3D‐Printed Bimetallic Metamaterials with Excellent Thermal‐Protection and Load Bearing Capacity

ABSTRACT Functional structures that combine thermal protection with load‐bearing capabilities represent an effective solution to hypersonic thermal‐protection challenges. Here, we propose a Janus‐like bio‐inspired strategy for integrally 3D‐printed bimetallic metamaterials. Inspired by shell bilayers, a heat‐resistant AlSiFeMnNiMg alloy and a SiC‐reinforced AlSi10Mg are arranged as an architected pair and fabricated via dual‐hopper selective laser melting, with SiC volume fractions of 0, 4, and 8 vol%. In situ SEM tensile tests at 25°C and 250°C show that damage is confined to a narrow transition zone. Once one side softens, the bimetallic architecture redirects load to the other, forming non‐percolating high‐stress paths and stabilizing the plateau response. Quasi‐static compression of Gyroid TPMS lattices with different SiC contents maps the composition‐temperature space. Across temperatures, structures with 4 vol% SiC improve specific energy absorption by 11.72% and 18.67% in room temperature and by 10.28% and 18.8% in 250°C, achieving synergistic mechanical improvement and a stable energy‐absorbing plateau under extreme environments. Relative to 0 and 8 vol%, where modulus mismatch precipitates premature localized collapse, 4 vol% SiC promotes a distributed shear‐band network that delays failure and elevates load capacity. This work provides a practical pathway toward thermally protective and load‐bearing integrated components for aerospace applications.