Microtruss materials are assemblies of struts or columns arranged periodically in space. The majority of past research efforts have focused on the key issue of microtruss architectural optimization. By contrast, this study focuses on the internal material structure at the level of the individual struts. Microstructural, geometrical, and material design techniques are used to improve their mechanical properties. The finite element method is used to verify and create predictive analytical models, explain the dependence of strut properties on geometry, material properties and failure mechanisms, and extend the strut design analysis into suggestions for the improvement of fabrication methods. Three strut design methods are considered. First, microstructural design is performed by considering the influence of strut geometry on the strain energy imparted during stretch bending. By using the perforation geometry to modify the location and magnitude of this strain energy, microtruss materials with lower density and higher strength can be fabricated. Second, structural sleeves of aluminum oxide and electrodeposited nanocrystalline nickel are used to reinforce architecturally optimized aluminum alloy microtruss assemblies, creating hybrid materials with high weight-specific strength. The mechanical properties are controlled by the interaction between material and mechanical failure; this interaction is studied through finite element analyses and a proposed analytical relationship to provide suggestions for further improvements. Finally, hollow cylindrical struts are fabricated from electrodeposited nanocrystalline nickel. The high strength to weight ratio achieved in these struts is due to the microstructural and cross-sectional efficiency of the material.

Microtruss materials are assemblies of struts or columns arranged periodically in space. The majority of past research efforts have focused on the key issue of microtruss architectural optimization. By contrast, this study focuses on the internal material structure at the level of the individual struts. Microstructural, geometrical, and material design techniques are used to improve their mechanical properties. The finite element method is used to verify and create predictive analytical models, explain the dependence of strut properties on geometry, material properties and failure mechanisms, and extend the strut design analysis into suggestions for the improvement of fabrication methods. Three strut design methods are considered. First, microstructural design is performed by considering the influence of strut geometry on the strain energy imparted during stretch bending. By using the perforation geometry to modify the location and magnitude of this strain energy, microtruss materials with lower density and higher strength can be fabricated. Second, structural sleeves of aluminum oxide and electrodeposited nanocrystalline nickel are used to reinforce architecturally optimized aluminum alloy microtruss assemblies, creating hybrid materials with high weight-specific strength. The mechanical properties are controlled by the interaction between material and mechanical failure; this interaction is studied through finite element analyses and a proposed analytical relationship to provide suggestions for further improvements. Finally, hollow cylindrical struts are fabricated from electrodeposited nanocrystalline nickel. The high strength to weight ratio achieved in these struts is due to the microstructural and cross-sectional efficiency of the material.