Multi-objective shape optimization of large strain 3D helical structures for mechanical metamaterials

The need for mechanical metamaterials with large strain range and lightweight properties are evidenced to engineering applications. In this regard, novel helical structures are proposed as suitable unit cell’s components of mechanical metamaterials. Three-dimensional helical structures composed of varying coil numbers, defined in a cylindrical spatial domain are shape optimized through genetic algorithm in a finite element script for conflicting objectives of minimum mass and maximum tensile range. The superior performance of the shape optimized helical structure is highlighted in terms of structural rigidity, large deformation capability, buckling and vibrational modal analysis in compare to equivalent coil springs of identical weight and comparable domain. Deformation mechanism is analyzed carefully to justify the improved performances of proposed structure. Tensile and compressive experimental analysis are undertaken to validate the enhanced strain ranges. One dimensional metamaterials implementations with various tessellation arrangements are simulated. Results show that the proposed design can effectively generate lightweight substitutes of metamaterials unit cells ligaments to improve the strain range performance. Planar and lattice metamaterial concepts employing shape optimized helical structure are illustrated to demonstrate the possibilities of promoting lightweight structural integrities in the design of mechanical metamaterials.