DESIGNING MECHANICAL METAMATERIALS FOR INDUSTRIAL APPLICATIONS

The doctoral thesis introduces a comprehensive methodology for designing, optimizing, and manufacturing mechanical metamaterials for industrial applications. Building upon recent theoretical advances in mechanical metamaterials—structures that derive their properties from geometric design rather than chemical composition—the research bridges the gap between computational frameworks and practical industrial implementation. The work employs a discrete element model (DEM) for efficient simulation of mechanical behaviors while maintaining essential accuracy through parameterization with finite element analysis. A Monte Carlo optimization approach combined with the Fast Inertial Relaxation Engine (FIRE) enables the systematic exploration of geometric configurations to achieve specific mechanical functionalities. The research demonstrates the effectiveness of additive manufacturing techniques, particularly Stereolithography (SLA) and Fused Deposition Modeling (FDM), in realizing complex metamaterial structures. Three significant industrial applications are presented: (1) a force-dispersing mechanical metamaterial for protective equipment developed in collaboration with Oberalp Group, which effectively redistributes localized forces across broader areas; (2) mechanical metamaterial actuators for Rold Srl's CB053 door latch and Flex Ltd.'s strip ejector, which transform directional motion without conventional mechanisms; and (3) a "metaspring" replacement for traditional springs in Rold's CD015 closure device. Physical validation through prototype testing confirms the computational predictions and demonstrates the practical viability of these metamaterial structures. This research establishes a transformative approach to industrial component design, reducing part counts, simplifying assembly processes, and enabling novel mechanical properties unattainable through conventional means. The methodology and findings open pathways for widespread industrial adoption of mechanical metamaterials across diverse sectors.