Mesoscale carbon fiber lattices with foam-like weight and bulk strength

Abstract

Abstract Carbon-fiber-reinforced polymers (CFRPs) are essential for lightweight transport and energy systems, but most current forms—particulate, short-fiber, or laminated— break the continuity of reinforcing fibers, interrupting load transfer and limiting strength, safety, and design freedom. Architected lattice materials offer a route to higher strength-to-weight ratios, yet prior CFRP lattices are largely confined to the microscale or rely on joints and segmented fibers that compromise load transfer. Here we demonstrate fully continuous three-dimensional CFRP lattices fabricated at the mesoscale using a 3D node winding process guided by algorithmic design. By systematically controlling fiber continuity at the lattice unit-cell level, these structures achieve specific strengths of up to 782 MPa·cm³·g⁻¹ at foam-like densities, representing a considerable achievement in mesoscale CFRP lattice architectures. Unlike conventional CFRPs, the lattices fail progressively through pseudo-ductile, damage-tolerant mechanisms with partial height recovery under compression. System-level demonstrations, including a robotic drone with substantially reduced frame mass and extended endurance, confirm scalability and practical relevance. This work establishes continuity-engineered CFRP lattices as a promising class of lightweight architected materials for next-generation structural systems.