Stress distribution in additive manufactured TPMS beams: FE simulation and thermoelastic stress analysis

This study investigates the stress distribution in beam-like structures composed of triply periodic minimal surface (TPMS) fabricated through additive manufacturing. Two topologies, Schwarz Primitive and Gyroid, were analyzed using a hybrid numerical–experimental approach combining Finite Element (FE) simulation and Thermoelastic Stress Analysis (TSA). Those methods were used to examine flexural behavior under static and dynamic loading conditions respectively. FE simulations revealed distinct stress distributions: the Gyroid structure exhibited localized regions with higher stress, while the Schwarz Primitive displayed a more uniform stress distribution. TSA, a non-contact, full-field technique sensitive to dynamic loading, confirmed these patterns, showing good agreement with the FE predictions. A three-point bending test was also conducted to provide further validation of mechanical performance. The results highlight the influence of TPMS geometry on stress distribution and show that integrating FE and TSA provides a reliable investigation of architected materials. This is, to the authors’ best knowledge, the first attempt to apply TSA to TPMS lattices, enabling full-field experimental validation of numerically predicted stress distributions. This framework offers promising potential for the design and validation of functionally graded and mechanically efficient components in structural, biomedical, and aerospace applications.