Engineering Flow Anisotropy in Additively Manufactured Lattices via Patterned Unit Cell Symmetry

Abstract

Additively manufactured lattice structures have become a staple of optimized structural parts and are increasingly common in biomedical and chemical applications that require consideration of flow through porous architectures. However, design principles governing transport performance trail those established for mechanical optimization. Here, we introduce two complementary design frameworks that modify symmetry at both the unit cell and part scales to systematically tune internal transport. These approaches are further extended into patterned lattice structures, where multiple unit cell designs can be combined in one, two, or three dimensions to further regulate the internal flow. We find that identical global lattice geometries can arise from different unit cell basis and voxel plane orientations, with minimal changes in bulk geometric properties. Yet in parts with diameters of 12–35 mm, hydraulic diameters of 1–4 mm, and porosities ~80%, these design selections significantly affect the hydraulic tortuosity and fluid transport behavior. We further demonstrate performance from select designs that yield a new class of anisotropic lattices with strong sensitivity to flow direction that is tuned by the projected area perpendicular to flow. Collectively, these symmetry-informed, multi-order combinatorial design approaches enable predictable, direction-dependent transport design and expand the functional potential of lattice architectures across disciplines.