Engineers at the University of Maine have discovered a new way to make 3D-printed parts both stronger and lighter—an important step forward for industries like aerospace, automotive, and medical devices.
The team, working at the university’s Advanced Structures and Composites Center (ASCC), has developed a method that helps designers better predict how well lightweight plastic parts will hold up under pressure.
This means they can now create more reliable and efficient components without using extra material.
The research team included Philip Bean, a research engineer at the ASCC; Senthil Vel, a professor of mechanical engineering; and Roberto Lopez-Anido, a professor of civil engineering.
Their findings were recently published in the journal Progressive Additive Manufacturing.
Their new method combines advanced computer modeling with real-life experiments to get a clearer picture of how 3D-printed parts behave when they’re put under stress.
This is especially useful when parts are made to be as light as possible—something that’s hard to analyze using traditional methods.
The team focused on something called “gyroid infill,” which is a complex, repeating structure often used inside 3D-printed objects. The gyroid pattern is special because it helps reduce weight while still keeping the part strong.
Think of it like a high-tech honeycomb hidden inside a plastic shell. This internal design isn’t visible from the outside, but it plays a big role in how the part performs.
To test how well the gyroid structure works, the researchers first used computer simulations to see how it would react to different forces. Then, they 3D-printed sample parts and tested them in the lab to compare the results. The close match between the simulations and the actual test results showed that their method works well.
“This work allows us to design 3D-printed parts with greater confidence and efficiency,” said Bean. “By understanding the precise strength of these gyroid-infilled structures, we can reduce material use and improve performance across industries.”
This breakthrough could help companies save money and materials while still making high-quality products. Whether it’s for building lighter airplane parts, safer car components, or better medical devices, this research opens new doors for the future of manufacturing.
In the long run, this method could help make 3D printing even more powerful and practical, turning creative designs into real-world solutions that are both strong and sustainable.
