This new material, made from a titanium alloy through an innovative, nature-inspired lattice design, holds significant potential for industries ranging from aviation to medical technology.

The research, supported by RMIT's Advanced Manufacturing Precinct and the Microscopy and Microanalysis Facility at the university, and funded by the Australian Research Council, has produced a super material that achieves a strength-to-weight ratio previously unattainable with current manufacturing methods. The key to this achievement lies in the unique lattice structure of the material, inspired by strong natural forms such as the giant water lily and tubular coral.

The Science Behind the Material

Professor Ma Qian, who leads the research team, explains the challenges in replicating these natural structures in metal, which traditionally suffered from uneven stress distribution and manufacturability issues. By leveraging advanced 3D printing technology, especially the laser-assisted metal powder bed fusion technique, the team has overcome many hurdles. This fusion technique involves layering metal powder and melting it with a high-powered laser to achieve precise and complex geometric shapes that distribute pressure more evenly across the structure.

The super material's design incorporates a hollow tubular lattice with a thin internal strut, working together to enhance strength and durability. "This hollow tubular lattice design containing a thin internal strut demonstrates unprecedented strength and lightness that have never been seen together in nature. By effectively merging two integrated lattice structures for even pressure distribution, we avoid typical stress concentration points," Qian states.

Performance and Potential Applications

In tests conducted within the Advanced Manufacturing Precinct, the titanium lattice cube displayed 50% greater strength than the strongest cast magnesium alloys currently used in aerospace applications. Not only does this demonstrate its superior strength, but it also highlights its ability to deflect cracks along the structure, enhancing durability.

Jordan Noronha, the study's lead author and a PhD candidate at RMIT, highlights the material's adaptability across different levels and its suitability for a variety of applications due to its strength, biocompatibility, and resistance to corrosion and heat. He notes that the structure can be produced in sizes ranging from several millimeters to several meters, using different types of printers, reflecting the wide potential for implementation in high-performance material-required sectors such as aircraft or rocket parts.

Future Trends and Challenges

While the technology needed to produce such advanced materials is not yet widely available, the RMIT team is optimistic about their adoption and application in the future. The material's ability to withstand temperatures up to 600 degrees Celsius, with further improvements, opens up potential uses in high-temperature environments such as aerospace and firefighting drones.

The transition from laboratory to industrial applications poses challenges due to the specialized equipment needed for production. However, as 3D printing technology advances, it is expected to become more accessible, speeding up the manufacturing process and broadening its application range.

The creation of this new super material represents an important step forward in materials science, offering a glimpse into the future of manufacturing where strength does not come at the expense of weight. As RMIT continues to refine these materials and explore their applications, the possibility of integrating them into various high-demand industries looks promising. This innovation not only highlights the capabilities of modern manufacturing techniques but also sets a new standard for material performance across industries.