Mechanical study of hybrid gyroid and foam structures under compression effects

This study evaluates the mechanical behavior of Gyroid triply periodic minimal surface (TPMS) structures filled with polyurethane foams of different densities under quasi-static compression. Key performance indicators were analyzed, including energy absorption per unit weight and volume, mechanical efficiency and the evolution of the failure mechanism. The Gyroid architecture, characterized by a high strength-to-weight ratio and uniform stress distribution, was combined with foams of varying density to assess how multi-material hybridization influences structural response. Differences in density significantly affected the onset of collapse, plateau behavior and specific energy absorption. The results show that hybrid Gyroid–foam configurations provide superior early-stage energy absorption and improved mechanical efficiency compared with single-density foam systems, without a significant increase in mass. These findings demonstrate the potential of hybrid TPMS-based energy absorbers for weight-critical applications in the aerospace, automotive and wearable protection sectors.