Innovative architectures for enhanced compressive strength: exploring the potential of 3D-printed short carbon fiber-reinforced polypropylene double-gyroid lattices

This study explores the compressive behavior of 3D-printed single- and double-gyroid solid-network lattices. Where the double gyroids are constructed from two intertwined single-gyroid structures. These structures were designed by nTop implicit modeling tool and then fabricated by material extrusion additive manufacturing method at optimized printing parameters. The main objective of this study is to investigate the compressive behavior of a novel double-gyroid lattice structure, aiming to overcome limitations of traditional cellular designs by offering enhanced energy absorption, progressive failure modes, and tunable mechanical response—particularly through the variation of gyroid heights. Standard polymer tests were performed; considering thermogravimetric analysis, the compression results demonstrate that increasing the relative density enhances both the mechanical properties and failure resistance in both architectures. For instance, a 32% increase in relative density from 0.5 to 0.66 for double gyroids led to a 102% increase in peak load. Distinct failure modes were observed; single-gyroid structures exhibited shear failure at approximately 45°, while double-gyroid structures failed via densification, showing a more gradual failure behavior. This controllable failure mode enabled by varying the gyroid height, demonstrates a more gradual and predictable collapse mechanism. The findings highlight how relative density and architectural design influence mechanical response, offering practical design guidance for lightweight applications in aerospace and automotive sectors.