Superior fracture resistance and topology-induced intrinsic toughening mechanism in 3D shell-based lattice metamaterials

Lattice metamaterials have demonstrated remarkable mechanical properties at low densities. As these architected materials advance toward real-world applications, their tolerance for damage and defects becomes a limiting factor. However, a thorough understanding of the fracture resistance and fracture mechanisms in lattice metamaterials, particularly for the emerging shell-based lattices, has remained elusive. Here, using a combination of in situ fracture experiments and finite element simulations, we show that shell-based lattice metamaterials with Schwarz P minimal surface topology exhibit superior fracture resistance compared to conventional octet truss lattices, with average improvements in initiation toughness up to 150%. This superiority is attributed to the unique shell-based architecture that enables more efficient load transfer and higher energy dissipation through material damage, structural plasticity, and material plasticity. Our study reveals a topology-induced intrinsic toughening mechanism in shell-based lattices and highlights these architectures as a superior design route for creating lightweight and high-performance mechanical metamaterials.