Progress in Additive Manufacturing, 2026 (ESCI, Scopus)
This study involved parametric genetic algorithms with computational and experimental validation to establish a robust framework for designing and optimizing biomimetic polar cylindrical lattice structures. A thorough examination of six different FCC topologies revealed that deformation topology, which is stretching-dominated rather than bending-dominated, exerts an additional influence on mechanical performance beyond relative density. Stretching-dominated structures, particularly the FCC-Core and FCC-Mesh, demonstrated remarkable energy absorption, high stiffness (elastic modulus up to 168.1 MPa), and superior compressive strength (up to 25.48 MPa), rendering them ideal for high-load applications such as orthopaedic implants. In contrast, bending-dominated structures, such as the FCC-Leaf, prioritized compliance and ductility and were suitable for soft-tissue interfaces. Finite element analysis (FEA) indicated high predictive accuracy (< 8.5% error) up to 50% strain, with deviations at higher strains attributable to manufacturing imperfections. The strong correlation between experimental data and Gibson–Ashby coefficients confirmed the reliability of the models, with exponents effectively classifying the fundamental deformation mechanisms. These findings provide a critical design paradigm: FCC-Core for maximal strength, FCC-Petal for efficient stiffness, and FCC-Ring/Mesh for balanced and tenable performance, thus enabling the data-driven creation of application-specific lattice materials for advanced engineering and biomedical fields.