Modeling damage and fracture in additively manufactured polymeric triply periodic minimal surface lattices

Abstract

Architected triply periodic minimal surface (TPMS) lattices offer superior specific energy absorption, toughness, fatigue strength, and tunability. While recent advancements have established rate-dependent viscoplastic constitutive models to capture the complex nonlinear deformation response of additively manufactured polymeric TPMS structures, predicting fracture and the resulting structural failure remains a significant challenge. We address this by performing systematic experiments on unit cells and lattices of various sizes under tension, compression, and non-monotonic loading. The experiments inform the development of a new constitutive model that captures the damage and fracture behavior of polymeric TPMS lattices. We first implement a high-fidelity viscoplastic deformation constitutive model from Ma et al. (2026) into finite element software Abaqus/Explicit via a user material subroutine. We then propose a damage initiation criterion for amorphous polymers based on stored elastic energy and equivalent plastic strain. The damage model is implemented in Abaqus using gradient-damage framework following Konale and Srivastava (2025). The damage model and numerical simulation capability are quantitatively and qualitatively validated using experimental results for a unit cell under non-monotonic loading and lattices under tension. The proposed damage model and simulation capability enable in silico design of architected polymer structures.