Microlattice represents an advancement in material science, offering a unique combination of strength and ultralight weight. This innovative material enables the creation of components previously unimaginable due to weight or performance limitations. It opens avenues for significant improvements across various industries.
Understanding Microlattice
Microlattice is a synthetic, porous material predominantly composed of air, giving it an extremely low density. It features an open cellular structure made of interconnected hollow tubes, or struts, arranged in a three-dimensional lattice. These individual struts are incredibly thin, often measuring around 100 nanometers in wall thickness, approximately 1,000 times thinner than a human hair. This arrangement forms a network of air pockets, accounting for up to 99.99% of its volume. Inspired by structures like human bone, the material derives its strength from its intricate, repeating geometric pattern rather than solid mass.
Remarkable Characteristics
Microlattice is renowned for its ultralight weight, often cited as being 100 times lighter than Styrofoam, with some samples having a density as low as 0.9 kg/m³, less than that of water. It exhibits a high strength-to-weight ratio. The material also possesses exceptional energy absorption capabilities, behaving similarly to elastomers. It can be compressed to more than 50% of its volume and almost completely recover its original shape. This flexibility allows it to dissipate large amounts of energy without breaking, making it highly resistant to impact and vibration.
Crafting Microlattice
The creation of microlattice involves a precise fabrication process that leverages photopolymer technology. The method begins with a photocurable resin that hardens into a polymer when exposed to ultraviolet (UV) light. Researchers use a technique called self-propagating photopolymer waveguide formation, where UV light is shone through a photomask at different angles into a tank of the resin. This process creates a three-dimensional polymer lattice, as the light causes the resin to polymerize and also helps channel more light, forming continuous structures.
Once the polymer lattice is formed, it is then coated with a thin metallic layer, typically an alloy like nickel-phosphorus, using an electroless plating process. This ensures a uniform coating across the intricate polymer structure. After the metal coating is applied, the underlying polymer template is dissolved away using a specific solution, leaving behind the hollow, interconnected metallic microlattice. This multi-step process allows for the creation of precise, micro-scale structures, enabling controlled porosity and tailored properties.
Real-World Applications
Microlattice’s combination of ultralight weight, high strength, and superior energy absorption makes it suitable for diverse real-world applications. In aerospace, it offers potential for reducing aircraft weight, improving fuel efficiency. It can be used for structural components, internal panels, stowage bins, floor panels, and for impact and shock absorption. For the automotive industry, microlattice can contribute to lightweight vehicle bodies and enhanced crash protection, improving passenger safety and vehicle performance.
Beyond these major industries, microlattice is also being explored for use in sports equipment. Its high surface area to volume ratio also makes it suitable for compact and lightweight heat transfer mechanisms, finding potential in energy harvesting systems and advanced battery development. It also suggests applications as a damping material across various sectors.