Periodic Minimal Surface Structures Research Articles

Multifunctional Design of Triply Periodic Minimal Surface Structures for Temporary Pediatric Fixation Devices

Fracture fixation and limb deformity correction in pediatric orthopedics often use temporary metallic fixation devices. These devices’ higher stiffness compared to cortical bone leads to stress shielding, causing significant bone density reduction, periprosthetic loosening, and bone growth interference. The 3D‐printed triply periodic minimal surface (TPMS) structures present a promising engineering solution to match bone stiffness while ensuring reliable implant strength. In this study, finite‐element modeling and experimental testing are employed to identify optimal multifunctional TPMS‐based lattices that meet the required design constraints of 1) stiffness in the range of cortical bone, 2) strength in the range of cortical bone, 3) minimum osteointegration to facilitate the implant removal after healing, and 4) manufacturability with limited defect sensitivity. Six different types of TPMS structures in Ti–6Al–4V material manufactured via laser powder bed fusion are evaluated for their ability to target the lower and upper bounds of pediatric cortical bone stiffness. Lattices based on the Primitive unit cell design are superior, demonstrating the highest strength/stiffness ratio, best manufacturability, and potentially reduced osteointegration due to larger pore size, smaller surface area, and smallest negative Gaussian curvature compared to other investigated TPMS types.

Study on isotropic design of triply periodic minimal surface structures under an elastic modulus compensation mechanism

The energy absorption characteristics of the triply periodic minimal surfaces (TPMS) structure may vary significantly due to the anisotropy under multi-directional loading conditions. To address this issue effectively, an isotropic design strategy based on a precise elastic modulus compensation mechanism for different TPMS lattices is proposed. This strategy involves combining a TPMS lattice with a high elastic modulus in the axial direction with another TPMS lattice featuring a low elastic modulus in the same direction, leveraging the complementary effects of elastic modulus to achieve isotropy. The relationship between the relative density and the elastic modulus of six types of TPMS lattices is analyzed through homogenization simulation and finite element analysis. Mathematical expressions are then fitted using the Gibson-Ashby model. Additionally, a Kriging model is employed to establish the relationship between the Zener anisotropy values of hybrid TPMS structures and the relative density of their component lattices. This enables the precise complementary effect of elastic modulus in different TPMS lattice structures, providing a widely applicable selection rule for achieving isotropy. Using the Primitive-Diamond hybrid lattice as an example, the Zener anisotropy index after hybridization is reduced by 65.2 % and 31.37 % compared to single Primitive and Diamond lattices, respectively.

Performance-based inverse structural design of complex gradient triply periodic minimal surface structures based on a deep learning approach

Triply periodic minimal surface (TPMS) structures have excellent mechanical performance compared to other lattice structures, but the process of reversely designing complex TPMS structures according to desired requirements is difficult due to the multiple structural parameters. In this study, a new deep learning approach (Balance-CGAN), consisting of a forward property prediction network and an inverse structural design network, was proposed to reversely design the gradient energy absorbing TPMS structures. The forward fully connected neural network (FCNN) was employed as the mechanical model for predicting TPMS structural performance, while the conditional generative adversarial network (CGAN) was used for further inverse structural design, and both networks were integrated by the target loss function. The Balance-CGAN method was proved to be effective in designing TPMS structures that meet the target performance criteria, with the minimum design error for the specified target being 4.6 %. The forward prediction accuracy of FCNN directly impacted the inverse design accuracy of the Balance-CGAN, with the error between the actual and target performance of the structure rising from 4.6 % to 14.6 % as the forward prediction error increased from 3.8 % to 11.3 %. This work provides a reference for the design and additive manufacturing of new industrial energy absorbing TPMS structures with specific mechanical properties using machine learning techniques.

Dynamic compressive behavior of functionally graded triply periodic minimal surface cellular structures

The Triply Periodic Minimal Surface (TPMS) structure is regarded as a porous structure used for impact protection due to its lightweight, high strength, and high specific energy absorption (SEA). This paper investigates the dynamic mechanical properties of the TPMS structure by Split Hopkinson Bar (SHPB) experiments and finite element analysis (FEA). We compare stress peak, SEA, strain rate effect, and deformation pattern for functionally graded Primitive (P), uniform P, and uniform Gyroid (G) structures. It is found that the increasing magnitude of peak stress in the TPMS structures becomes more evident under high-impact loads. As the relative density increases, the strain rate effect becomes more prominent. The uniform G structures exhibit higher plateau stress and SEA than uniform P structures. Besides, graded P structures exhibit a climbing phenomenon compared to uniform P structures in the platform section. The FEA results also demonstrate that higher SEA and plateau stresses are exhibited in the graded P structure. The graded design minimizes the strain rate effect compared to the corresponding uniform structures. It is essential to set a properly graded index to enhance the dynamic energy absorption capacity of the TPMS structure, as more fluctuations occur when the graded index increases.

Effects of aging heat treatment on the mechanical properties of NiTi triply periodic minimal surface

This study investigated the impact of aging heat treatment time on the mechanical properties of NiTi triply periodic minimal surface structures fabricated through laser powder bed fusion. X-ray diffraction analysis results indicate that with increasing aging time, the NiTi2 phase precipitates while the content of the B19’ phase decreases. At 10 h of aging time, the Ni4Ti3 phase becomes evident in the sample. The differential scanning calorimeter results show that R phase transformation occurs, and the phase transformation temperature increases when the aging time reaches 6 h. Microhardness increases with aging time, peaking at 477.8 HV after 10 h. Compression experiment results reveal a maximum elastic modulus of 1262.82 MPa for the gyroid sheet-shaped structure achieved after 2 h. In addition, the superelasticity test indicates the highest recoverable strains at 2%, 4%, and 6% compressive strain for the gyroid rod-shaped structure after aging for 10 h. In cyclic compression experiments, the ratio of shape memory recovery increases from 40% at 0 h to 97% at 6 h. Fracture analysis results show that the transition in the fracture mechanism from brittle fracture to quasi-cleavage fracture occurs after aging heat treatment.

Mechanical Behaviour of Photopolymer Cell-Size Graded Triply Periodic Minimal Surface Structures at Different Deformation Rates.

This study investigates how varying cell size affects the mechanical behaviour of photopolymer Triply Periodic Minimal Surfaces (TPMS) under different deformation rates. Diamond, Gyroid, and Primitive TPMS structures with spatially graded cell sizes were tested. Quasi-static experiments measured boundary forces, representing material behaviour, inertia, and deformation mechanisms. Separate studies explored the base material's behaviour and its response to strain rate, revealing a strength increase with rising strain rate. Ten compression tests identified a critical strain rate of 0.7 s-1 for "Grey Pro" material, indicating a shift in failure susceptibility. X-ray tomography, camera recording, and image correlation techniques observed cell connectivity and non-uniform deformation in TPMS structures. Regions exceeding the critical rate fractured earlier. In Primitive structures, stiffness differences caused collapse after densification of smaller cells at lower rates. The study found increasing collapse initiation stress, plateau stress, densification strain, and specific energy absorption with higher deformation rates below the critical rate for all TPMS structures. However, cell-size graded Primitive structures showed a significant reduction in plateau and specific energy absorption at a 500 mm/min rate.

Mechanical evaluation of elastomeric thermoplastic polyurethane additively manufactured triply periodic minimal surface area lattice structures for adjustable cushioning properties

PurposeCushioning is a useful material property applicable for a range of applications from medical devices to personal protective equipment. The current ability to apply cushioning in a product context is limited by the appropriateness of available materials, with polyurethane foams being the current gold standard material. The purpose of this study is to investigate additively manufactured flexible printing of scaffold structures as an alternative.Design/methodology/approachIn this study, this study investigates triply periodic minimal surface (TPMS) structures, including Gyroid, Diamond and Schwarz P formed in thermoplastic polyurethane (TPU), as a possible alternative. Each TPMS structure was fabricated using material extrusion additive manufacturing and evaluated to ASTM mechanical testing standard for polymers. This study focuses attention to TPMS structures fabricated for a fixed unit cell size of 10 mm and examine the compressive properties for changes in the scaffold porosity for samples fabricated in TPU with a shore hardness of 63A and 90A.FindingsIt was discovered that for increased porosity there was a measured reduction in the load required to deform the scaffold. Additionally, a complex relationship between the shore hardness and the stiffness of a structure. It was highlighted that through the adjustment of porosity, the compressive strength required to deform the scaffolds to a point of densification could be controlled and predicted with high repeatability.Originality/valueThe results indicate the ability to tailor the scaffold design parameters using both 63A and 90A TPU material, to mimic the loading properties of common polyurethane foams. The use of these structures indicates a next generation of tailored cushioning using additive manufacturing techniques by tailoring both geometry and porosity to loading and compressive strengths.

Thermal-hydraulic performance of modified Schwartz-Diamond solid-networks triply periodic minimal surface structures

The triply periodic minimal surface (TPMS) structures are widely used as disturbance core structure in high performance heat exchangers. In this paper, four modified Schwartz-Diamond solid-networks (SD-solid) TPMS structures, one structure compressed along the flow direction (β = 2), and three structures compressed along the spanwise direction (α = 2, α = 3, and α = 4) are designed. Flow and heat transfer processes in the structures are studied with computational fluid dynamics (CFD) and experimental method. The performance enhancement criterion (PEC) is employed to evaluate the overall heat transfer performance. As the results of simulation, the overall heat transfer coefficient (hoverall) of α = 2, α = 3, and α = 4 is 10.04 %, 34.34 %, and 62.03 % higher than that of SD-solid respectively. The PEC of α = 2, α = 3, and α = 4 structures is 27.35 %, 34.17 %, and 34.95 % higher than that of the original SD-solid structure, respectively. Two samples of them (β = 2 and α = 2) are fabricated using additive manufacturing and their thermal–hydraulic performance is experimented on a flow and heat transfer experimental platform. Comparing the experimental results of the hoverall, the β = 2 structure is 68.5 % higher and the α = 2 structure is 23.06 % higher than the original SD-solid structure. However, for the average pressure drop, the β = 2 structure is 448.5 % higher and the α = 2 structure is 66.77 % lower than the original SD-solid structure. It is proved that the modified SD-solid structure compressed along the spanwise direction has the performance of enhancing heat transfer and reducing the pressure drop.

Vat photopolymerization 3D printing SiBCN ceramic metamaterials with strong electromagnetic wave absorption

Starting from the simulation prediction, SiBCN polymer-derived-ceramic metamaterials, integrating both structure and function in a single component, were obtained using vat photopolymerization technology starting from a preceramic polymer. The low-density gyroid triply periodic minimal surface (TPMS) structures used in this study increases the multiple reflection loss of electromagnetic wave (EMW) in the macro-interpenetrating channel structure, generates surface characteristics (stair-stepping effect) structure interface polarization, and improves microwave absorption characteristics. The possible multiple reflection effects of a gyroid structure on electromagnetic waves are discussed by Computer Simulation Technology simulation. At the same time, the precipitated phases in polymer derived ceramics (PDCs) were adjusted by controlling the pyrolysis temperature. The results show that the crystal phases (such as β-SiC and C) precipitated in the gyroid structure sample pyrolyzed at 1200°C enrich the heterogeneous interface polarization in the material. In addition, C forms a (semi-)conductive network, which increases the conductivity loss. The effective absorption bandwidth (EAB, RL<-10 dB) of the samples pyrolyzed at 1200°C was 3.09 GHz (thickness of 2.21 mm) and the minimum reflection loss (RLmin) was −70.6 dB (thickness of 2.31 mm), indicating that the samples have favorable EMW absorption properties and great potential for applications, providing a foundation for the preparation of high-performance lightweight structural ceramics.

Development of biodegradable Zn-based porous scaffolds with elaborate triply periodic minimal surface structure via Vat photopolymerization-assisted template replacement strategy

Herein, a novel strategy, namely Vat photopolymerization-assisted template replacement method was developed to achieve elaborate triply periodic minimal surface structure and different pore sizes in biodegradable Zn-based porous scaffolds. The pore structure, microstructure, phase constitution, degradation properties, mechanical performance, in vitro cytocompatibility and antibacterial activity were systematically investigated. As a result, triply periodic minimal surface structures with different pore sizes were successfully obtained in Zn–1Mg porous scaffolds. The actual porosity closely matched the designed porosity, demonstrating the efficacy of the new strategy in achieving precise pore structures with a difference below 2%. Zn–1Mg scaffolds, designed with a pore size of 780 mm, exhibited a uniaxial compressive strength of 59.95 MPa and an elastic modulus of 3.07 GPa. Furthermore, the mechanical integrity was well-maintained even after 28 days of immersion, attributed to the substantial deposition of calcium-phosphate-rich corrosion products within the porous structure. More importantly, a suitable weight loss rate of about 15% were confirmed after 28 days immersion, indicating a period for total degradation of approximately 13 months based on a linear degradation assumption. Further, the experimental scaffolds demonstrated good cytocompatibility with MC3T3-E1 preblast cells and exhibited significant antibacterial activity against both Staphylococcus aureus and Escherichia coli.

Novel path planning algorithm for laser powder bed fusion to improve the scan quality of triply periodic minimal surface structures

Traditional path planning methods, such as contour and raster methods, suffer from problems like uneven filling, overfilling, and underfilling in the sliced layers, resulting in poor continuity of the lattice melt pool, internal porosity defects, and severe powder adhesion at the contour edges, while research on path planning for three-periodic minimal surfaces lattices is relatively limited. In this study, a scanning path planning method based on lattice equations control is proposed, which differs from traditional contour paths and raster paths. The new paths are controlled by the isosurface parameters of the lattice equation and optimized using the traveling salesman problem, resulting in more uniform scanning paths. The new paths avoid the underfilling issue present in raster path and the sawtooth-shaped borders of raster path. Additionally, they circumvent the nonuniform scanning path problem caused by uneven wall thickness in contour path. Through visualizing the paths and conducting printing experiments on the lattice, it is found that the new path is more uniform compared to contour paths, effectively addressing the issue of overfilling. Compared to raster paths, the new path has smoother boundaries and reduces internal porosity and powder adhesion within the lattice. This research has important value in reducing internal porosity and external powder adhesion issues in three-period minimal surface (TPMS) lattice printing processes, further enhancing the manufacturing quality of TPMS lattices.

Quasi-static compressive fracture behavior of three-period minimum surface Al2O3 / Al composites fabricated by stereolithography

Extensive research has been conducted on the structures and preparation methods of ceramic/metal composites to achieve materials with superior strength and toughness. Among these, the triply periodic minimal surface (TPMS) structure stands out due to its remarkable advantages. In this study, we employed SLA additive manufacturing to fabricate a Gyroid-structured ceramic skeleton, and utilized metal infiltration to prepare interpenetrating Al2O3/Al composites. A comparison was made between the compressive properties of Al2O3/Al interpenetrating composites with Gyroid curved surface structure and those with honeycomb structure. The experimental outcomes indicate that compressive failure in both structural composites primarily occurs at the bond interface between the ceramic framework and the metal. These composites exhibit brittle fracture and experience shear failure. Furthermore, the compressive failure mechanism involves a mixed fracture composed of cleavage and micropore polymerization fractures. Gyroid curved structural composites exhibit lower local stress concentration due to their smooth and regular topology, rendering them with higher strength and ductility compared to honeycomb structural composites. The ultimate compressive strength of the Gyroid curved composite is 264 MPa, representing a 3.8-fold increase over the honeycomb structure.

Enhanced convective heat transfer in new triply periodic minimal surface structures: Numerical and experimental investigation

Triply Periodic Minimal Surfaces (TPMS) structures are increasingly recognized for their potential in thermal management due to their unique repetitive and interconnected minimal surfaces. However, a major challenge lies in enhancing the convective heat transfer performance of TPMS structures. This study introduces new TPMS designs and evaluates their thermal characteristics against established structures such as Diamond, Gyroid, SplitP, and Lidinoid employing a combination of numerical simulations and experimental measurements. The results reveal that the newly TPMS designs significantly outperform existing ones in terms of heat transfer performance. Numerically, the new TPMS structures demonstrate improvements in the Nusselt number and convective heat transfer coefficient, ranging from 6% to 13.7% and 4.6% to 20%, surpassing Lidinoid and SplitP, and eclipsing Diamond and Gyroid by 15% to 58% and 37% to 91%, respectively. Experimentally, these findings are complemented with the newly TPMS structures showing increases in convective heat transfer coefficients up to 68% and a 57% rise in Nusselt numbers compared to the Gyroid structure. These enhancements are attributed to their larger fluid-solid contact areas and optimized fluid distribution. However, a trade-off is observed in the form of increased pressure drops in the more complex TPMS structures, particularly in structures with larger circumferences and periodicities. The study also highlights the complex dynamic flow patterns within these structures, establishing a direct link between design complexity and fluid dynamics. This interconnectedness is pivotal for future design optimizations aimed at improving thermal performance. These findings represent a significant step forward in TPMS research, paving the way for further investigations into optimizing these structures for superior heat transfer performance.

Optimization of Environment-Friendly and Sustainable Polylactic Acid (PLA)-Constructed Triply Periodic Minimal Surface (TPMS)-Based Gyroid Structures.

The demand for robust yet lightweight materials has exponentially increased in several engineering applications. Additive manufacturing and 3D printing technology have the ability to meet this demand at a fraction of the cost compared with traditional manufacturing techniques. By using the fused deposition modeling (FDM) or fused filament fabrication (FFF) technique, objects can be 3D-printed with complex designs and patterns using cost-effective, biodegradable, and sustainable thermoplastic polymer filaments such as polylactic acid (PLA). This study aims to provide results to guide users in selecting the optimal printing and testing parameters for additively manufactured/3D-printed components. This study was designed using the Taguchi method and grey relational analysis. Compressive test results on nine similarly patterned samples suggest that cuboid gyroid-structured samples perform the best under compression and retain more mechanical strength than the other tested triply periodic minimal surface (TPMS) structures. A printing speed of 40 mm/s, relative density of 60%, and cell size of 3.17 mm were the best choice of input parameters within the tested ranges to provide the optimal performance of a sample that experiences greater force or energy to compress until failure. The ninth experiment on the above-mentioned conditions improved the yield strength by 16.9%, the compression modulus by 34.8%, and energy absorption by 29.5% when compared with the second-best performance, which was obtained in the third experiment.

Energy Absorption Capability of Graded Hybrid Triply Periodic Minimal Surface Structures Based on Fracture Zone Controlling

A novel design strategy of the graded hybrid energy‐absorbing lattice structure is proposed by controlling fracture zone. The primitive (P) and iWP (W) structures are two kinds of triply periodic minimal surface structures with typical deformation and failure modes. Thus, taking the P (stretching‐dominated) and the W structures (bending‐dominated) as object, the deformation and failure mechanisms of two structures are studied. Then, the PWP (i.e., the fracture zone of the P structure filling with the W structure) and WPW (i.e., the fracture zone of the P structure filling with the W structure) structures with uniform and gradient change are designed. The structures are fabricated using stereolithography appearance process and compressed under quasistatic conditions. And the energy absorption capacity comparison of these structures is studied. The experimental results show that the maximum energy absorption efficiency of the PWP structure is 38.85% higher than that of the P structure and the densification energy absorption of the WPW structure is 66.67% higher than that of the W structure. Additionally, gradient design can effectively improve the densification energy absorption of lattice structure. The novel structural design greatly contributes to customized energy absorption design of lattice structures.

Rotating Flow and Heat Transfer Characteristics of a Novel Cooling Channel for Gas Turbine Blade Trailing Edge With Diamond-Type TPMS Structures

Abstract This work designs a Diamond-type triply periodic minimal surface (TPMS) structure that exhibits excellent thermomechanical properties in a gas turbine blade trailing edge to enhance thermal performance and improve heat transfer uniformity. Since the velocity and temperature distributions are altered in the rotating trailing edge channel, the flow and heat transfer characteristics of the baseline pin fin and Diamond TPMS models are numerically investigated at the Reynolds number of 10,000 and the rotation numbers of 0.0–0.28. Compared to the baseline model, the Diamond TPMS network significantly decreases recirculation flow at the inner wall, improving heat transfer, especially at the tip and outlet regions. Although the Diamond TPMS model incurs substantial pressure losses from 191% to 234%, it yields significantly higher overall heat transfer than the pin fins by 179%. Consequently, the thermal performance increased by 93.4%. The flow fluctuations due to the rotating effects are minor in the Diamond TPMS architecture, considerably reducing the differences in heat transfer between the leading and trailing walls. The differences in the wetted-area averaged Nusselt number of the baseline and Diamond TPMS models within the studied rotation numbers are 8.5–14.4% and about 8.5%, respectively. Moreover, the Diamond TPMS structure reduces the differences in heat transfer between the root and tip regions at the outlet by up to 80% compared to the pin fins. This improvement helps protect the trailing edge from thermal failure, thereby potentially prolonging the gas turbine blade's lifetime.

On fracture mechanism of additively manufactured triply periodic minimal surface structures using an explicit phase field model

Triply periodic minimal surface (TPMS) structures have been extensively studied for their exceptional mechanical characteristics. However, numerical analysis of their fracture behaviour remains insufficient due to the complexity of the fracture mechanism. This study aims to utilise a new phase field model to predict the mechanical responses and analyse the fracture mechanism of TPMS gyroid (G) and primitive (P) structures. Firstly, the G and P structures were additively manufactured using Ti-6Al-4 V titanium and tested under both axial and oblique compression. Secondly, an explicit phase field model was developed by incorporating the Bao-Wierzbicki fracture model to capture damage initiations. It was found that the developed explicit phase field model enables accurate reproduction of experimental force-displacement responses, deformation modes, crack initiations and propagations for G and P structures under both loading conditions. It was found that medium stress triaxiality tension was the dominant stress state to trigger material damage, regardless of structure and loading condition. Moreover, compared with axial compression, oblique loading introduced a more non-proportional loading history, leading damage initiation points far away from the fracture locus. Further, in comparison with the G structure, the P structure involved more medium and high stress triaxiality tension induced fracture initiations, resulting in more damaged material points. This study offers valuable insight into the fracture mechanism of TPMS structures, which is beneficial to improving the design of these structures.

Piezoresistive Porous Composites with Triply Periodic Minimal Surface Structures Prepared by Self-Resistance Electric Heating and 3D Printing.

Three-dimensional flexible piezoresistive porous sensors are of interest in health diagnosis and wearable devices. In this study, conductive porous sensors with complex triply periodic minimal surface (TPMS) structures were fabricated using the 3D printed sacrificial mold and enhancement of MWCNTs. A new curing routine by the self-resistance electric heating was implemented. The porous sensors were designed with different pore sizes and unit cell types of the TPMS (Diamond (D), Gyroid (G), and I-WP (I)). The impact of pore characteristics and the hybrid fabrication technique on the compressive properties and piezoresistive response of the developed porous sensors was studied. The results indicate that the porous sensors cured by the self-resistance electric heating could render a uniform temperature distribution in the composites and reduce the voids in the walls, exhibiting a higher elastic modulus and a better piezoresistive response. Among these specimens, the specimen with the D-based structure cured by self-resistance electric heating showed the highest responsive strain (61%), with a corresponding resistance response value of 0.97, which increased by 10.26% compared to the specimen heated by the external heat sources. This study provides a new perspective on design and fabrication of porous materials with piezoresistive functionalities, particularly in the realm of flexible and portable piezoresistive sensors.

A Triply-Periodic-Minimal-Surface Structured Interphase based on Fluorinated Polymers Strengthening High-energy Lithium Metal Batteries.

The challenge of constructing a mechanically robust yet lightweight artificial solid-electrolyte interphase layer on lithium (Li) anodes highlights a trade-off between high battery safety and high energy density. Inspired by the intricate microstructure of the white sea urchin, we first develop a polyvinyl fluoride-hexafluoropropylene (PVDF-HFP) interfacial layer with a triple periodic minimal surface structure (TPMS) that could offer maximal modulus with minimal weight. This design endows high mechanical strength to an ordered porous structure, effectively reduces local current density, polarization, and internal resistance, and stabilizes the anode interface. At a low N/P ratio of ~3, using LiFePO4 as the cathode, Li anodes protected by TPMS-structured PVDF-HFP achieve an extremely low capacity-fading-rate of approximately 0.002 % per cycle over 200 cycles at 1 C, with an average discharge capacity of 142 mAh g-1. Meanwhile, the TPMS porous structure saves 50 wt % of the interfacial layer mass, thereby enhancing the energy density of the battery. The TPMS structure is conducive to large-scale additive manufacturing, which will provide a reference for the future development of lightweight, high-energy-density secondary batteries.

A Triply‐Periodic‐Minimal‐Surface Structured Interphase based on Fluorinated Polymers Strengthening High‐energy Lithium Metal Batteries

AbstractThe challenge of constructing a mechanically robust yet lightweight artificial solid‐electrolyte interphase layer on lithium (Li) anodes highlights a trade‐off between high battery safety and high energy density. Inspired by the intricate microstructure of the white sea urchin, we first develop a polyvinyl fluoride‐hexafluoropropylene (PVDF‐HFP) interfacial layer with a triple periodic minimal surface structure (TPMS) that could offer maximal modulus with minimal weight. This design endows high mechanical strength to an ordered porous structure, effectively reduces local current density, polarization, and internal resistance, and stabilizes the anode interface. At a low N/P ratio of ~3, using LiFePO4 as the cathode, Li anodes protected by TPMS‐structured PVDF‐HFP achieve an extremely low capacity‐fading‐rate of approximately 0.002 % per cycle over 200 cycles at 1 C, with an average discharge capacity of 142 mAh g−1. Meanwhile, the TPMS porous structure saves 50 wt % of the interfacial layer mass, thereby enhancing the energy density of the battery. The TPMS structure is conducive to large‐scale additive manufacturing, which will provide a reference for the future development of lightweight, high‐energy‐density secondary batteries.