Mechanical property analysis of triply periodic minimal surface structure with a novel hybrid structure

Triply periodic minimal surface（TPMS）structure, demonstrates significant advantages in vehicle design due to its excellent lightweight characteristics and mechanical properties. To enhance the mechanical properties of TPMS structures, this study proposes a novel hybrid TPMS structure by combining Primitive and Gyroid structures using level set equations. Following this, samples were fabricated using selective laser sintering (SLS). Finite element models for compression simulation were constructed by employing different meshing strategies to compare the accuracy and simulation efficiency. Subsequently, the mechanical properties of different configurations were comprehensively investigated through uniaxial compression testing and finite element analysis (FEA). The findings indicate a good agreement between the experimental and simulation results, demonstrating the validity and accuracy of the simulation model. For TPMS structures with a relative density of 30%, meshing with S3R elements proved optimal. Unlike the deformation modes of Gyroid and Primitive structures, in hybrid structures, deformation and yielding occur in the lower-middle part of the component. Then, the deformation extends upward, eventually leading to the compaction of the component. Notably, the hybrid structure demonstrated a 34.9% and 8.8% increase in specific energy absorption compared to the Primitive and Gyroid structures, respectively. Additionally, the mean crushing force of the hybrid structure improved by 44.25% and 6.9%, respectively. The load-carrying fluctuation capacity of the hybrid structure was less than 11%, indicating good energy absorption efficiency. This study underscores the potential of hybrid TPMS structures to significantly enhance the mechanical performance of vehicle components, contributing to advancements in lightweight design and crashworthiness.