Advances in cross-scale mechanical optimization of 3D lattice structures

Abstract Three-dimensional (3D) lattice structures exhibit unique mechanical properties, including a negative Poisson’s ratio and enhanced energy absorption, which make them superior to conventional materials. This study investigates the optimization mechanisms of three cross-scale design strategies—hierarchy, gradient, and disorder—on the mechanical performance of 3D lattices. By combining hierarchical topological reconstruction, gradient parameter adjustments, and disorder algorithms, 3D lattices significantly improve energy absorption, dynamic response, and multifunctional integration. These optimization strategies provide solutions for high-performance applications, such as impact protection and bone repair scaffolds, which are facilitated by advancements in additive manufacturing (AM) and intelligent optimization. However, challenges remain in multi-material AM and high-load integration, requiring further development to realize the full potential of 3D lattices. Future research will enhance their applicability, particularly in aerospace, biomedical, and energy absorption fields, thereby supporting the next generation of metamaterial systems.