The reliable experimental characterization of architected lattice materials under cyclic loading requires accurate fixture systems that ensure proper load transfer without introducing parasitic effects. This study presents the design and validation of testing fixtures optimized using density-based topological optimization techniques for performing cyclic load tests on lattice structures. The supports were manufactured with PLA filaments and evaluated using finite element simulation and experimental testing. The results show that the final design achieved a safety factor of 4.25, significantly improving on the initial value of 2.08. Likewise, the optimized supports showed reduced deformations by around 80% compared to the machine clamps, ensuring rigid and reliable stress transfer. In particular, while the metal structure of the test system showed deformations of several millimeters, the optimized PLA supports recorded displacements around 0.73 mm, confirming that they remain virtually rigid and ensure correct transmission of forces to the Kelvin-type structure. These findings confirm the viability of using PLA as an alternative to conventional metal devices in fixtures for mechanical testing of lattice materials.

Hot forging of Ti-6Al-4V is extensively utilized in the manufacture of orthopedic implants; however, the coupled influence of strain rate and temperature on ductile damage evolution during the forging of femoral stems remains insufficiently quantified. In this study, a finite element framework is developed to analyze and optimize the hot forging process, incorporating strain rate- and temperature-dependent plasticity, as well as the Johnson–Cook damage criterion. Mesh convergence is established, and the assumption of quasi-adiabatic conditions is substantiated via Péclet number analysis. A full factorial design is implemented by varying the ram velocity (0.1–0.5 m/s) and initial billet temperature (850–950 °C) to evaluate the forging load, stress triaxiality, equivalent plastic strain, and damage accumulation. Results indicate that process kinetics govern the mechanical response: increasing the ram velocity enhances strain-rate hardening, resulting in higher peak loads, while explicitly reducing stress triaxiality and suppressing ductile damage evolution. Conversely, temperature exhibits a secondary influence within the investigated domain. Validation of the damage criterion confirms safe operating windows, identifying low-velocity forging as a high-risk condition for localized defect formation. These findings provide practical guidelines for the strain-rate-based optimization of thermomechanical processing parameters for Ti-6Al-4V femoral stems.