Metamaterials, also known as lattice‐structured materials, imitate the multifunctionality of natural architects as tailoring their physical properties is associated with manipulating their microstructure. As the recent evolution of additive manufacturing enables the creation of intricate geometries with minimal material wastage, improving the design to manufacturing cycle of lattice structured materials has become one of the trending research areas. Triply periodic minimal surface (TPMS) and plate lattice materials are renowned for their exceptional mechanical behavior in lightweight applications. Apparently, several types of design optimization strategies are explored to maximize their performance for better biocompatibility and mechanical loading resistance. Some of these strategies include functional gradation and multimorphology hybridization that are comprehensively described in this review. Their benefits and drawbacks are highlighted with a focus on TPMS and plate lattice materials. The review anticipates the utilization of automated design exploration methods (i.e., topology optimization and data‐driven methods) to further enhance the design optimization procedure of lattice structured materials.

Thermal history and residual stresses in dissimilar friction stir welding (FSW) of AA2024 and AZ31 were studied under different tool offsets using a coupled Eulerian–Lagrangian (CEL) finite element model and a mechanical model. Welding experiments and residual stresses' measurements were conducted to validate the models. Comparisons between the experimental and numerical results indicated good agreement. The maximum temperature in the welded zone was predicted to be slightly lower than 400 °C, regardless of offset, and that its location shifted with tool offset from the advancing side (AS) to the retreating side (RS). Longitudinal residual stresses changed from tensile under the tool shoulder to compressive beyond this region and it appeared to be the dominant stress component. The transverse stresses were tensile and of lower magnitude. Both the longitudinal and transverse residual stresses have their maximum values within the weld zone near the end of the weld length. For both peak temperatures and residual stresses, higher values were obtained at the AS with no tool offset and 1 mm offset to the AS, and at the RS with 1 mm offset to the RS. Lower residual stresses and better weld quality were obtained with tool offset to the aluminum side.