Breaking better: How imperfections increase fracture resistance in architected lattices

Abstract

Fracture behavior in architected materials can be influenced by heterogeneities, yet the mechanisms by which imperfections affect crack propagation remain poorly understood. In this study, we introduce well-controlled, localized defects in the form of isolated missing struts to evaluate their impact on crack growth in brittle lattice specimens. Using mechanical testing combined with digital image correlation (DIC), we track crack propagation and identify failure processes at the scale of individual lattice cells. While the imperfections do not alter the location of crack initiation or the peak load, they consistently lead to an increase in work to failure when the crack path is tortuous or crack bridging occurs. These findings demonstrate how small, targeted modifications to an otherwise regular lattice can significantly influence fracture resistance in brittle architected materials.