The goal of this paper is to improve the mechanical strength-to-weight ratios of metal cubic lattice structures using unit cells with fillet shapes inspired by triply periodic minimal surfaces (TPMS). The lattice structures here presented were fabricated from AA6082 aluminum alloy using lost-PLA processing. Static and dynamic flat and wedge compression tests were conducted on samples with varying fillet shapes and fill factors. Finite element method simulations followed the static tests to compare numerical predictions with experimental outcomes, revealing a good agreement. The TPSM-type fillet shape induces a triaxial stress state that significantly improves the mechanical strength-to-weight ratio compared to fillet radius-free lattices, which was also confirmed by analytical considerations. Dynamic tests exhibited high resistance to flat impacts, while wedge impacts, involving a high concentrated-load, brought out an increased sensitivity to strain rates with a short plastic deformation followed by abrupt fragmentation, indicating a shift towards brittle behavior.

The kinematic synthesis of compliant mechanisms based on flexure hinges is not an easy task. A commonly used method is the equivalent rigid model, which involves replacing the flexure hinges with rigid bars connected with lumped hinges using the already known methods of synthesis. This way, albeit simpler, hides some interesting issues. This paper addresses the elasto-kinematics and instantaneous invariants of flexure hinges with a direct approach, making use of a nonlinear model to predict their behaviour. The differential equations that govern the nonlinear geometric response are given in a comprehensive form and are solved for flexure hinges with constant sections. The solution to the nonlinear model is then used to obtain an analytical description of two instantaneous invariants: the centre of instantaneous rotation (c.i.r.) and the inflection circle. The main result is that the c.i.r. evolution, namely the fixed polode, is not conservative but is loading-path dependent. Consequently, all other instantaneous invariants are loading-path dependent, and the property of instantaneous geometric invariants (independent of the motion time law) can no longer be used. This result is analytically and numerically evidenced. In other words, it is shown that a careful kinematic synthesis of compliant mechanisms cannot be addressed by only considering the kinematics as rigid mechanisms, and it is essential to take into consideration the applied loads and their histories.