A study on the 3D printing preparation method of reinforced casings for lithium-ion batteries in energy storage power stations using high specific energy absorption metamaterials

Additive manufacturing has enabled the development of advanced lattice and metamaterial structures with tailored mechanical performance for energy absorption and lightweight structural applications. In this study, a novel round gyroid triply periodic minimal surface (TPMS) metamaterial is designed, fabricated 3D printing, and systematically investigated under quasi-static compression loading. A combined experimental and finite element method (FEM) approach is employed to evaluate the mechanical response and validate the numerical model. The FEM results show excellent agreement with experiments, with only 1.3% deviation in stiffness and 5.8% difference in ultimate compressive load, confirming the high accuracy of the developed simulation framework in capturing the complex deformation behavior of the proposed architecture. The deformation analysis reveals a progressive and stable collapse mechanism governed by distributed plasticity and strain localization within the gyroid network. A comprehensive parametric study is then conducted to investigate the influence of structure thickness (T) and unit-cell height (H) on mechanical performance. The results demonstrate that T is the dominant parameter controlling load-bearing capacity and energy absorption, while H mainly influences deformation evolution with limited impact on global response. Importantly, the structure exhibits exceptionally high specific energy absorption (SEA), reaching up to 2586.5 mJ/g, significantly increasing with thickness and showing only minor variation (1–3%) with changes in H. This highlights the robustness and tunability of the proposed design for energy dissipation applications. Overall, the findings confirm that the proposed round gyroid TPMS metamaterial introduces a new geometry-driven strategy for achieving high-performance, lightweight, and highly efficient energy-absorbing structures.