Digital precision in engineered ceramics: Tailoring toughness and flexibility through interlocking strategies

Abstract

Precise material architectures and interfaces can render conventional ceramics tough, deformable and damage-resistant, offering a wide range of possibilities beyond those provided by conventional ones. This study explores the mechanical properties of topologically interlocked ceramic panels by systematically varying architectural parameters (i.e., interlocking angles and building block sizes) using a combination of experimental testing and finite element modeling based on COMSOL Multiphysics®. Three distinct designs were fabricated using digital laser manufacturing, categorized as designs with constant interlocking angles and tile sizes, constant interlocking angles and variable tile sizes, and variable interlocking angles and tile sizes and subjected them to out-of-plane quasi-static loads. The results show substantial enhancements in toughness (up to 110%) and strength (up to 120%) for ceramics with varying building block sizes, compared to those with constant block sizes. Additionally, these ceramics exhibit increased flexibility (up to 130%) compared to plain ceramics. Larger interlocking angles contribute to superior mechanical properties, fostering increased energy absorption and stability. The study also investigates post-failure behavior, revealing that increasing length ratios consistently augment the energy absorption. This research highlights the potential of these materials for flexible protection and the importance of controlling architectural parameters based on the interlocking angle and building block size to optimize performance while minimizing damage.