Summary
- Triply-twinned lattice: three mirror planes make struts stretch, not bend, boosting stiffness.
- Up to 380% stiffer and 279% stronger than cubic lattices while using the same material.
- Less sensitive to micro-defects; changing print orientation can halve defect failures.
A team of researchers from University College London (UCL) have developed a new 3D-printable structure called a “triply-twinned” lattice that is up to 380% stiffer and 279% stronger than ordinary cubic designs. Best of all, it uses the same amount of material!
This could have major implications for many 3D‑printed components and applications — particularly where lightweight stiffness and strength matter — but adoption will depend on validation across specific materials, printing methods, part sizes and application standards.
What is “triply-twinned” lattice?
This could solve one of the biggest issues 3D printers have
This new lattice shape looks a little like a snowflake or kaleidoscope, and works similarly. A triply-twinned lattice has three planes of mirror symmetry, which change how forces pass through the structure. The study, published in Advanced Materials, applies microscopic crystal structures to macroscopic engineering lattices to change how loads are carried.
In fields like modern engineering, there’s a constant problem of balancing weight against structural integrity. Components made from solid metal or plastic end up being too heavy and inefficient. Standard lattice structures tend to bend under load, which isn’t stable or mechanically efficient.
To address this, the UCL team, led by researcher David McArthur and supervised by Dr. Chu Lun Alex Leung, adopted a concept called “crystal twinning,” where crystal structures are symmetrically mirrored across certain planes. By incorporating three planes of symmetry into each cubic lattice unit, the geometry causes struts to stretch rather than bend under compression. Because stretching transmits load efficiently, the final structure is nearly three times stronger and up to 3.8 times stiffer than a conventional lattice, without adding any extra material. Neat!
Imaging also revealed that micro-defects such as small pores or rough surfaces often led to fractures, but the twinned lattice’s overall performance was less sensitive to these defects. Finally, the team found that simply changing a part’s orientation during 3D printing could reduce defect-related failures by up to half.
For this new lattice design to become common in the future, a few things have to happen first. 3D printing software and design tools need to add these new shapes so people can actually use them. Manufacturers have to make sure the design works with different materials, such as metals, plastics, and materials that are safe for the human body. There also need to be official rules and tests so engineers know the design is safe and reliable in real products. Once all of this is done, this new technology can go from being just a lab experiment to something people actually use in the real world.
