Abstract:Three types of truss rod unit lattice structures were nested within the honeycomb cavities to obtain a new honeycomb-nested lattice structure. Using AlSi10Mg powder as the material, samples with different relative densities of the new bcc honeycomb-nested lattice structure (HC-N-bcc), honeycomb-nested symmetric rod lattice structure (HC-SP), new fluorite-type honeycomb-nested lattice structure (HC-N-F), and hollow honeycomb structure (HC-E) were fabricated by the selective laser melting (SLM) technique. Lateral compression mechanical properties, macro-micro deformation mechanisms, and energy absorption analyses were conducted on these samples. The results show that the lateral compression performance of the honeycomb-nested lattice structures is significantly superior to that of the hollow honeycomb structure. At the relative density of 46%, the HC-SP structure exhibits a compression modulus and peak stress that are 43% and 44.7% higher than those of HC-E, respectively. Under the strain of 50%, its energy absorption () and crushing force efficiency (CFE) are 7.7 and 5.3 times higher than those of HC-E, respectively. When truss unit lattices are embedded in the honeycomb cavities, the honeycomb shell deforms gradually and uniformly instead of fracturing instantly, significantly improving the compressive stability of the honeycomb structure. Furthermore, the larger the proportion of the truss volume in the overall structure, the better the performance improvement of the honeycomb-nested lattice structure.