Load Distributing Metamaterials Via Discrete Optimization

Detry A, Holey H, Zulkarnain R, Guerra R, Papa I, Zaiser M, Zapperi S (2026)

Publication Type: Journal article

Publication year: 2026

Journal

Advanced Functional Materials Wiley-VCH Verlag

DOI: 10.1002/adfm.77938

Abstract

Mechanical metamaterials promise unprecedented control over load transfer by tailoring mesoscale architecture, yet most design strategies optimize global stiffness or energy absorption and only indirectly affect force redistribution. Here we introduce a computational–experimental framework to explicitly design load-distributing metamaterials by minimizing the variance of reaction forces transmitted to a support interface. Starting from a 3D face-centered cubic (FCC) beam lattice, we model deformation using a linear-elastic Timoshenko beam formulation and perform discrete topology optimization via Monte Carlo simulated annealing, where individual struts are selectively activated or removed. We demonstrate both single-objective optimization for a prescribed indenter position and a multi-objective formulation that enforces robust performance across multiple loading locations. Simulations show that optimized architectures transform highly localized support reactions into substantially more homogeneous force footprints, reducing the fraction of nearly unloaded nodes and capping peak forces. Stereolithography-printed elastomeric lattices validate these predictions: quasi-static pressure mapping reveals suppressed force hotspots and enlarged contact areas, while instrumented impact tests show earlier, more spatially distributed deformation and markedly improved repeatability–especially for off-center loading in multi-objective designs. This work establishes load homogenization as a primary, quantifiable design target for architected materials, enabling protective interfaces and supports with tunable and robust force-spreading behavior.

Authors with CRIS profile

Michael Zaiser Lehrstuhl für Werkstoffsimulation

Involved external institutions

Università degli studi di Milano IT Italy (IT) Università degli Studi di Napoli Federico II IT Italy (IT)

How to cite

APA:

Detry, A., Holey, H., Zulkarnain, R., Guerra, R., Papa, I., Zaiser, M., & Zapperi, S. (2026). Load Distributing Metamaterials Via Discrete Optimization. Advanced Functional Materials. https://doi.org/10.1002/adfm.77938

MLA:

Detry, Andrea, et al. "Load Distributing Metamaterials Via Discrete Optimization." Advanced Functional Materials (2026).

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