KAIST

< (From left) Professor Seunghwa Ryu of KAIST Department of Mechanical Engineering, Professor Tobin Filleter of the University of Toronto, Dr. Jinwook Yeo of KAIST, and Dr. Peter Serles of the University of Toronto >

Recently, in advanced industries such as automobiles, aerospace, and mobility, there has been increasing demand for materials that achieve weight reduction while maintaining excellent mechanical properties. An international joint research team has developed an ultralight, high-strength material utilizing nanostructures, presenting the potential for various industrial applications through customized design in the future.

KAIST (represented by President Kwang Hyung Lee) announced on the 18th of February that a research team led by Professor Seunghwa Ryu from the Department of Mechanical Engineering, in collaboration with Professor Tobin Filleter from the University of Toronto, has developed a nano-lattice structure that maximizes lightweight properties while maintaining high stiffness and strength.

In this study, the research team optimized the beam shape of the lattice structure to maintain its lightweight characteristics while maximizing stiffness and strength.

Particularly, using a multi-objective Bayesian optimization algorithm*, the team conducted an optimal design process that simultaneously considers tensile and shear stiffness improvement and weight reduction. They demonstrated that the optimal lattice structure could be predicted and designed with significantly less data (about 400 data points) compared to conventional methods.

*Multi-objective Bayesian optimization algorithm: A method that finds the optimal solution while considering multiple objectives simultaneously. It efficiently collects data and predicts results even under conditions of uncertainty.

< Figure 1. Multi-objective Bayesian optimization for generative design of carbon nanolattices with high compressive stiffness and strength at low density. The upper is the illustration of process workflow. The lower part shows top four MBO CFCC geometries with their 2D Bézier curves. (The optimized structure is predicted and designed with much less data (approximately 400) than the conventional method >

Furthermore, to maximize the effect where mechanical properties improve as size decreases at the nanoscale, the research team utilized pyrolytic carbon* material to implement an ultralight, high-strength, high-stiffness nano-lattice structure.

*Pyrolytic carbon: A carbon material obtained by decomposing organic substances at high temperatures. It has excellent heat resistance and strength, making it widely used in industries such as semiconductor equipment coatings and artificial joint coatings, where it must withstand high temperatures without deformation.

For this, the team applied two-photon polymerization (2PP) technology* to precisely fabricate complex nano-lattice structures, and mechanical performance evaluations confirmed that the developed structure simultaneously possesses strength comparable to steel and the lightness of Styrofoam.

*Two-photon polymerization (2PP) technology: An advanced optical manufacturing technique based on the principle that polymerization occurs only when two photons of a specific wavelength are absorbed simultaneously.

Additionally, the research team demonstrated that multi-focus two-photon polymerization (multi-focus 2PP) technology enables the fabrication of millimeter-scale structures while maintaining nanoscale precision.

Professor Seunghwa Ryu explained, "This technology innovatively solves the stress concentration issue, which has been a limitation of conventional design methods, through three-dimensional nano-lattice structures, achieving both ultralight weight and high strength in material development."

< Figure 2. FESEM image of the fabricated nano-lattice structure and (bottom right) the macroscopic nanolattice resting on a bubble >

He further emphasized, "By integrating data-driven optimal design with precision 3D printing technology, this development not only meets the demand for lightweight materials in the aerospace and automotive industries but also opens possibilities for various industrial applications through customized design."

This study was led by Dr. Peter Serles of the Department of Mechanical & Industrial Engineering at University of Toronto and Dr. Jinwook Yeo from KAIST as co-first authors, with Professor Seunghwa Ryu and Professor Tobin Filleter as corresponding authors.

The research was published on January 23, 2025 in the international journal Advanced Materials (Paper title: “Ultrahigh Specific Strength by Bayesian Optimization of Lightweight Carbon Nanolattices”).

DOI: https://doi.org/10.1002/adma.202410651

This research was supported by the Multiphase Materials Innovation Manufacturing Research Center (an ERC program) funded by the Ministry of Science and ICT, the M3DT (Medical Device Digital Development Tool) project funded by the Ministry of Food and Drug Safety, and the KAIST International Collaboration Program.