Additive manufacturing of architected structures for thermal signature reduction in multifunctional stealth armored vehicles: A comparative study with conventional camouflage netting

Thermal signature management is a crucial aspect of Infrared (IR) stealth technology in both military and civilian applications, particularly for armored vehicles and critical infrastructure. This study develops a 3D-printed architected structure inspired by natural minimal surfaces, designed to suppress thermal signatures and enhance concealment of armored vehicles. The structure was parametrically modified to create a dual-component signature management system for IR reduction: SM1, with a relative density of 15%, achieved reduced measured thermal signatures, while SM2, with a relative density of 20%, exhibited slower thermal-response behavior under the examined experimental conditions. Controlled variations in relative density also influenced the observed IR signature distribution through differences in internal void arrangement and surface geometry. The proposed system was evaluated against existing solutions under representative service conditions during three independent experimental campaigns, with comparisons performed against a double-layer camouflage net configuration and armor steel coated with a standard military coating. IR thermography was employed to monitor temperature evolution over time under direct and angled sunlight. Two performance indices were developed to quantitatively assess the systems: the Symmetric Percentage Difference and the Thermal Signature Management-to-Cost Ratio. A life cycle cost (LCC) framework was established to evaluate the economic viability of the proposed system. Despite the camouflage net benefiting from double-layer coverage and military surface treatment, the bio-inspired 3D-printed architected structures demonstrated superior thermal performance, providing lower thermal signatures, improved thermal blending with the surrounding environment, and cost benefits. These findings indicate that additively manufactured, stealth-variable layers provide a viable and versatile approach to thermal (IR) signature management, with potential applications across defense, aerospace, critical infrastructure, and operational platforms.