Energy Absorption Mechanisms in Minimal Surface Versus Truss-like Lattice Structures: Experimental and Numerical Insights.

Truss-like and minimal surface-based cells are among the promising candidates for novel impact-resistant structural designs. However, the influence of cell configurations on impact resistance performance remains unclear. In this paper, the energy absorption characteristics of three truss-like cells (BCC, Fluorite, and Diamond) and three minimal surface cells (Gyroid, Primitive, Diamond) are systematically compared using quasi-static compression experiments and refined numerical models. Experimental results indicate that minimal surface cells possess clearly superior specific energy absorption performance. Specifically, the Gyroid (G-surface) exhibits a specific energy absorption (25 kJ/kg) approximately 2.3 times greater than the highest value among truss-like cells (11 kJ/kg), accompanied by an extended plateau strain by about 20%. Additionally, due to stress concentration at joints, truss-like cells show notably lower plateau forces compared to minimal surface cells. However, truss-like cells demonstrate better manufacturing precision and quality control, as evidenced by a relatively small average weight deviation (about 1.2%). Furthermore, numerical simulations were conducted to explore differences in deformation mechanisms between two representative cells. Results reveal that the BCC structure absorbs energy through localized shear band formation induced by point plastic hinges, whereas the Primitive (P-surface) minimal surface structure achieves more uniform plastic deformation via distributed line plastic hinges. Finally, impact simulations of protective structures show that the maximum stress in the P-surface-filled structure is reduced by 4.6% compared to the BCC-filled structure, and stress distribution uniformity is improved by 37%. The findings from this study provide valuable references and data support for future anti-impact structural designs.