Development and optimization of novel 3D printed Weaire–Phelan structures: a comprehensive comparative analysis

This study investigated the development and optimization of bio-inspired Weaire–Phelan lattice structures fabricated using fused deposition modelling (FDM) with PLA and ABS materials. The influence of critical printing parameters, including the build axis, infill density, and raster angle, on tensile strength, impact energy, and wear characteristics was systematically analysed using Taguchi Weighted Grey Relational Analysis. Experimental results revealed that optimization of the FDM process parameters improved the mechanical performance of both PLA and ABS specimens. PLA printed using the optimal process parameters (Z-axis build orientation, 80% infill density, and 45° raster angle) exhibited superior overall performance, achieving a 16.7% improvement in tensile strength and an 8% increase in absorbed impact energy, while optimized ABS specimens showed approximately 15% enhancement in impact resistance. These parameters of both PLA and ABS were subsequently used to fabricate the Weaire–Phelan lattice structures for the comparative studies. The optimized Weaire–Phelan lattice structures demonstrated nearly 17% higher tensile strength and 10% greater impact energy absorption compared with conventional PLA printed structures fabricated under the same optimized process parameters. The study confirms that the combined effect of FDM process parameter optimization and bio-inspired lattice architecture significantly improves the mechanical performance of 3D-printed components. These findings provide useful design guidelines for lightweight and high-performance applications in the aerospace, automotive, and biomedical engineering sectors. The improvement in wear performance is associated with optimization of the FDM processing parameters, whereas the Weaire–Phelan lattice was experimentally validated for enhanced tensile and impact performance.