AI-Designed 3D Printed Nano-Materials: Stronger Than Steel, Lighter Than Foam

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AI-Designed 3D Printed Nano-Materials: Stronger Than Steel, Lighter Than Foam

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The future of space travel and many other industries will depend on mankind developing stronger, lighter, and more readily available materials. From steel to carbon fiber, all the way to today’s most advanced nano-architected materials, the quest to create durable featherweight components remains a priority across a multitude of sciences. Thankfully, a team of researchers led by the University of Toronto’s Faculty of Applied Science & Engineering recently introduced a new process that has shown some promising results. Here’s what you need to know.

Nano-Architected Materials

In terms of high performance, nano-architected materials are among the strongest. They utilize diverse shapes on a nanoscale to create high levels of resilience. These shapes are repeated hundreds or thousands of times. This configuration produces unique load conditions and nanoscale side effects that add to their strength,

Notably, since their invention, there have been many different versions of nano-architectured materials, each using different shapes and sizes, such as lattices, gyroids, honeycombs, and hybrid geometries. While these materials have been proven to provide added strength, there have been some drawbacks to this tech to date.

Problem with Today’s Nano-Architected Materials

One of the main drawbacks of nano-architected materials currently is that they have hard failure and breakage points. The structure of these items and the use of standard lattice shapes means that corners and intersections are subject to added stress. Consequently, the lack of proper stress distribution can lead to sudden catastrophic failures at the nodes and junctions.

Nano-Architected Materials Study

Recognizing these limitations, a group of researchers created a unique machine learning algorithm to research and develop possible new architectures. The study called Ultrahigh Specific Strength by Bayesian Optimization of Carbon Nanolattices¹ was published in Advanced Materials.

This study represents the first time that machine learning has been applied to the creation of nano-architectured materials. Notably, the AI algorithm combined various aspects of material science, chemistry, and mechanics to accurately model the performance of different configurations, materials, and shapes. The goal of the research is to leverage the “smaller is stronger” effect that nanomaterial provides.

The team began their operations by leveraging the Bayesian optimization machine learning algorithm. This AI algorithm is ideal compared to other options due to its use of fewer data points. The Bayesian optimization machine learning algorithm only requires 400 data points versus the thousands required by other algorithms.

The algorithm analyzed and tested different complex 3D structures. It reviewed key data points like stress locations and breaking pressure while registering the high-resolution characterization of the pyrolytic carbon atomic structure. The data was then used to optimize the new structure to improve the strength-to-weight ratio further.

Nano-Architected Materials Test

To test their theory, the engineers 3D-printed Four cubic-face centered cubic (CFCC) lattice generative designs with optimized beam shapes using the two-photon polymerization 3D printer located in the Centre for Research and Application in Fluidic Technologies (CRAFT). This device enabled multi-focus multi-photon polymerization. Specifically, the printed test subjects consisted of 18.75 million nanometer-sized lattice cells.

Notably, the lattice used an acrylic polymeric structure that was then heated to crosslink the polymer into a glassy aromatic carbon. This step reduced the overall size by 20%. From there, a variety of pressure tests were conducted.

Nano-Architected Materials Test Results

The tests proved that the new nano-architected materials exhibited improvements in strength due to machine-learning beam element optimization, high-purity pyrolyzed carbon, and the ability to create nanoscale strut diameters. Specifically, the new designs ranked between 118% and 68% stronger than their predecessors.

Their structural efficiency improved as well. The test showed better stress and weight distribution and strength-to-weight ratios than the original designs. Specifically, the new material and design doubled the previous model’s strength, achieving .03 MPa m3 kg−1 at low densities.

Nano-Architected Materials Benefits

The benefits of using Bayesian-optimized designs and nano-architectured pyrolyzed carbon are easily noticeable at a glance. These materials provide more strength, weigh less, and can be customized to fit a wide variety of needs.

Strength

The nanomaterials and structure give these ultra-lightweight materials a strength-to-weight ratio greater than that of titanium. As such, this material could improve a variety of industrial and commercial tasks in the coming years.

Minimal Weight

The researchers concluded that their creation was as light as styrofoam, even though it outperformed steel in durability and strength tests. The key to the ultra-light design is the use of lower-density materials and components.  Specifically, the reduction of nanolattice strut diameters to 300 nm produces a unique high-strength carbon that outperforms predecessors.

Sustainability

The new material can help to reduce the high carbon footprint of flying in other industries that rely on lightweight composite material to operate. The reduction of materials in the manufacturing process directly results in added sustainability.

Customization

The printing process used to create the materials means that they can be built to fit nearly any use case, shape, or size. This added flexibility creates new opportunities for engineers to develop better systems that provide higher performance across multiple spectrums.

Nano-Architected Materials Researchers

Research for the nano architect materials was conducted at the University of Toronto’s Faculty of Applied Science & Engineering. It was led by Professor Tobin Filleter (MIE). He had assistance from  Peter Serles, Professor Seunghwa, and  Jinwook Yeo from the Korea Advanced Institute of Science & Technology (KAIST) in Daejeon, South Korea.

The research was a collaborative effort that brought together the Karlsruhe Institute of Technology (KIT) in Germany, the Massachusetts Institute of Technology (MIT), and Rice University in the United States, under the International Doctoral Clusters program.

Nano-Architected Materials Applications

There are several potential applications for this technology. From aerospace to the automotive industry, there’s a huge demand for lightweight durable materials. Here are just a few applications for these new nano-architectured materials.

Military

The military continues to look into lightweight material for everything from building vehicles to creating more effective body armor. This technological breakthrough could help the soldiers of tomorrow survive war zones more effectively and do more.

Automotive

The rise of EVs has created a race to find the lightest and most durable affordable materials available. The reason for this search is that EV battery life directly relates to the vehicle’s weight-to-power ratio. Reducing the weight of EV building material will result in much longer drive times.

Aerospace

Nano Architected materials have long found a home as ultra-lightweight components in aerospace applications. This material is ideal for creating components for planes, helicopters, and spacecraft. This lightweight design and composite build means that engineers can improve weight to weight-to-lift ratio without sacrificing safety.

Companies that could integrate Nano-Architected Materials and Benefit

There’s no shortage of companies that could benefit from stronger and lighter materials. These firms cover the entire market, from industrial manufacturers to protective gear and sporting equipment developments. Here’s one firm that could integrate this technology today and see immediate benefits.

TransDigm Group

TransDigm (TDG +1.58%) entered the market in 1993. It was founded in Cleveland, OH, as a aircraft parts producer. The company quickly expanded its operations and offerings which helped it to become a major player in the market.

Today, TransDigm is one of the top-recognized manufacturers of highly engineered aerospace components, systems, and subsystems. It has managed to remain a competitive force through innovation and several high-level acquisitions.

Introducing the lightweight and durable nano-architected materials developed by researchers would help the company create more durable options. The added weight reduction and strength would result in more value for consumers and better performance for manufacturers.

TransDigm has a market cap of $77.1B currently. The company is considered a “hold” by most analysts due to its positioning and proven track record. Those seeking a recognized and established aerospace manufacturing stock should consider reviewing TDG.

Nano-Architected Materials Have the Potential to Change the Game

When you examine the major upgrades that these lightweight materials bring to multiple industries, it’s easy to see that they are game changers. The use of lighter and stronger materials will upgrade multiple markets and provide engineers with added capabilities. As such, you have to commend the engineers for their efforts.

Learn about other Nanotech Here

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Study Reference:

^{1. Serles, P., Yeo, J., Haché, M., Guerra Demingos, P., Kong, J., Kiefer, P., Dhulipala, S., Kumral, B., Jia, K., Yang, S., Feng, T., Portela, C. M., Wegener, M., Howe, J., Singh, C. V., Zou, Y., Ryu, S., & Filleter, T. (2025). Ultrahigh specific strength by Bayesian optimization of carbon nanolattices. Advanced Materials, 37(5), 2410651. https://doi.org/10.1002/adma.202410651}

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January 30, 2025 at 07:22PM