Reduced Material Usage Research Articles

Ecodesign Enhancement of Polymeric Resins: Reinforcing with Synthetic and Natural Fibers Using Theory of Inventive Problem Solving-Algorithm of Inventive Problem Solving for Sustainable Composite Design

This study examines the enhancement of the mechanical strength of polymer resins through reinforcement with synthetic (glass) and natural (hemp, jute) fibers, using the TRIZ-ARIZ methodology to optimize composite design for improved mechanical properties, sustainability, and economic efficiency. Mechanical testing, thermogravimetric analysis (TGA), and scanning electron microscopy (SEM) were conducted to evaluate the properties of the composite materials. Regarding tensile strength testing, the results showed the following: jute fiber achieved the best results, with a maximum tensile values of 43.75 MPa (partial reinforcement) and 43.53 MPa (complete reinforcement); glass fiber recorded maximum tensile values of 34.55 MPa (partial reinforcement) and 34.52 MPa (complete reinforcement); and hemp fiber yielded maximum tensile values of 24.98 MPa (partial reinforcement) and 24.86 MPa (complete reinforcement). The mechanical performance of partial reinforcements (in the area of maximum stress) was similar to that of complete reinforcements, enabling a reduction in material usage by up to 60%. The thermal analysis (TGA) results demonstrated that glass fiber-reinforced composites exhibit high thermal stability, with mass loss starting at 320 °C and a residual mass of 8.02%; for other composite materials, thermal degradation begins at 305 °C, with a residual mass of 3.69%; in jute fiber-reinforced composites, thermal degradation starts at 300 °C, with a residual mass of 3.71%. SEM analysis generally revealed good fiber–matrix adhesion, while defects such as voids or detached fibers contributed to reduced mechanical strength. These results demonstrate that natural fiber-reinforced composite materials, particularly those reinforced with jute, can be used in sustainable engineering applications. They also show that localized reinforcement provides high performance with minimal resource consumption.

Surrogate-assisted optimization under uncertainty for design for remanufacturing considering material price volatility

Remanufacturing is a well-established end-of-life (EOL) strategy that promises significant savings in energy and carbon emissions. However, the current design practices are not remanufacturing-inclusive, i.e., the majority of products are designed for a single life cycle. As a result, potential products that can sustain multiple life cycles are deprived of additional benefits of being designed for remanufacturing, such as reduced material usage, lower cost, and improved environmental impact. Moreover, the uncertainty in design, material selection, and economics are not considered to produce remanufacturable designs. Accordingly, this research proposes a design for remanufacturing (DfRem) framework that accounts for design uncertainty and material price volatility. The framework systematically explores the design space, performs design optimization under uncertainty, followed by topology optimization to provide additional mass savings, and finally, a price volatility analysis for plausible design material choices. The candidate designs are evaluated based on their design mass, material price volatility, failure mode characteristics, carbon footprint, and embodied energy impacts. The proposed framework's utility is demonstrated via the use of an engine cylinder head case study subjected to thermo-mechanical loads along with fatigue and wear failure. Considering grey cast iron and aluminum alloy as the design material choices, it was found that the cast iron design reduced the initial design mass by 6% as opposed to a 5% decrease for aluminum. On the other hand, about 8% area of the cast iron design failed due to fatigue, compared to 3% for aluminum. We further observed that although the aluminum design provided better mechanical performance than the cast iron design, this material was more expensive and volatile in price.

Model decomposition method for minimizing the consumption of support structure for FFF

Fused filament fabrication (FFF) often requires additional support structures for manufacturing parts with overhanging areas, leading to substantial material and time wastage. Although several model decomposition techniques have been developed to tackle this issue, most focus solely on the constraint of overhang surface area. As a result, these techniques often struggle with parts that have intricate overhang characteristics, causing reduced printing surface accuracy and quality. This study introduces a precise method for detecting overhang regions and support-relevant overhang regions to improve the accuracy of overhang region identification and printing precision. Additionally, a model decomposition strategy leveraging genetic algorithm optimization is proposed to minimize the need for support structures, aiming for nearly support-free printing. Moreover, for intricate structures with a high topology where support structures are unavoidable, a novel projection support based on the distribution of periodic points in triangular form is developed to address this printing challenge. Experimental results demonstrate that the implementation of the algorithm outlined in this work on an FFF printer has achieved nearly support-free printing. Moreover, the proposed method for generating support structures has the potential to reduce material usage by 27 %.

Improving the tray footprint of retention and sustainable specific suspension (3S) packaging

One of the main issues with retention and suspension packaging is that objects tend to shift toward the sides inside the cardboard box due to impacts, reducing the available cushioning distance during subsequent impacts from the same direction. When a horizontal wrapper is employed to secure objects on a cardboard tray, various modifications are commonly made to address this issue in wrapped packaging. These modifications include adding friction foam underneath the object and altering the tray shape. A special case of wrapped packaging is 3S packaging, which stands for sustainable specific suspension packaging, which focuses on applying this stretch wrapping principle to e-commerce. Previous studies on 3S packaging have shown that a plain rectangular tray can only protect lightweight goods from multiple consecutive drops in the same direction, and increasing the wrapping density does not extend the applicable weight range. This study investigates alternatives for increasing wrapping density, demonstrating that adding friction to the tray is undesirable. Instead, a central narrowing proves to be the most promising option to ensure that the object remains protected from all sides during sequential impacts and expands the applicable range of the wrapped packaging methods. Additionally, incorporating steps into the transition of the central narrowing is beneficial for both the wrapping process and the shock absorption properties of these stretch-wrapped packaging methods. These findings allow for a reduction in material usage, better shock absorption, and faster packaging.

Crack-growth inhibition by designing dendritic pattern for soft adhesives

Soft adhesive layers show promise in various engineering applications, including biomedicine, automotive, semiconductor, and aerospace industries. However, cavities trapped at the interface due to poor contact will significantly inhibit their adhesion capacity, leading to rapid crack-growth failure. Significant efforts in these applications within a confined contact area are focused on mitigating the effects and enhancing the debonding work of the interface without changing the materials, such as using bioinspired micropillars. However, soft adhesives with isolated contact elements face limitations due to manufacturing complexity and the collision of micropillars under large deformation. This study proposes a simple and effective method to reduce the hydrostatic pressure around the crack tips by designing a dendritic pattern within the confined area. This approach inhibited interface crack growth well and improved adhesive performance. As a result, the crack failure was delayed, with the stretch ratio enhanced by more than 36 %, while the debonding work increased by 85 % compared with the circular adhesive layer. This study demonstrates that adhesion capacity can be significantly improved while reducing material usage by designing dendritic patterns.

Mechanical Analysis and Optimization of Concrete Structures Based on Advanced Finite Element Method

This article explores the mechanical analysis and optimization problems of concrete structures based on the Advanced Finite Element Method. By integrating advanced numerical techniques with practical engineering cases, this study aims to improve the safety and economy of concrete structure design. Firstly, the paper outlines the limitations of traditional finite element methods in concrete structure analysis, such as insufficient computational accuracy and low computational efficiency. Subsequently, by introducing AFEM, we significantly improved the accuracy and efficiency of the analysis. For example, when simulating a complex bridge structure, AFEM not only reduces the calculation time by about 25%, but also improves the accuracy of stress distribution prediction by more than 10%. In the optimization stage, we utilized the analysis results of AFEM and optimized the material consumption, cross-sectional dimensions, and reinforcement parameters of concrete structures through multi-objective optimization algorithms. A comprehensive data analysis underscores that the optimized concrete structure triumphantly meets all safety performance criteria while achieving a remarkable 12% reduction in material usage. This substantial material savings translates into a substantial 8% decrease in overall construction costs, significantly bolstering the project’s economic feasibility. Moreover, these cost savings not only amplify the project’s profitability but also play a pivotal role in enhancing the structure’s longevity and durability, thereby contributing to its sustainable performance over its entire service life. Furthermore, we delved into the capability of AFEM in simulating intricate phenomena such as the nonlinear behavior of concrete materials, crack propagation patterns, and the intricate interactions between steel reinforcements and concrete. These complex mechanical behaviors are crucial for the safety and stability of structures, and AFEM provides more comprehensive and accurate references for structural design by accurately simulating these behaviors. This article conducts in-depth research on the mechanical analysis and optimization of concrete structures based on AFEM, and demonstrates the significant advantages of AFEM in improving structural safety and economy through specific data. These research results not only provide new theoretical support and practical tools for concrete structure design, but also provide valuable references for future research and application in related fields.

In-situ synthesis of 2D nanozymes-coated cellulose nanofibers on paper-based chips for portable detection of biothiols

BackgroundSimple, fast and low-cost paper-based analytical devices (PADs) have a good application prospect for point-of-care detection of GSH. However, effective immobilization of functional nanomaterials onto cellulose, as a critical factor in the construction of PADs, presents numerous difficulties and challenges. ResultsIn this study, we have developed an exceptionally straightforward and environmentally friendly synthetic approach by using ovalbumin (OVA) as a bio-mineralization template for the preparation of MnO2 nanosheets. The MnO2 nanosheets produced in the solution phase exhibited excellent intrinsic nano-enzyme activity and biodegradability. The OVA-MnO2 nanosheets can effectively oxidize Amplex red in the absence of H2O2, enabling sensitive detection of GSH with a linear range of 5 nM–10 μM and a detection limit as low as 2.8 nM. Furthermore, we utilized this method to facilitate in situ synthesis of OVA-MnO2 nanosheets directly on paper substrates. This approach eliminates the need for conventional stirring and centrifugation steps, greatly simplifying the fabrication process while reducing material usage and time expenditure. Characterization of the chemical composition and morphology confirmed the intimate growth of the 2D nano-enzymes on the cellulose fibers. Utilizing smartphone capabilities, the OVA-MnO2 nanosheet-modified PAD enabled instrument-free detection of GSH, demonstrating high sensitivity (0.74 μM) and a wide linear response range (1–1000 μM). SignificanceThe synthesis of MnO2 nanosheets directly on cellulose substrates substantially streamlines the modification workflow of PADs and reduces detection costs, offering new avenues for clinical diagnostics of relevant diseases.

A novel design optimization framework to sustain remanufacturability

The ever-increasing global carbon emissions have urged the need for environmentally conscious/sustainable product design, for which the design for remanufacturing (DfRem) is one potential approach. DfRem targets at designing products that have multiple life cycles, thus significantly reducing raw material usage, energy consumption, and carbon emissions. In this paper, we develop a three-stage framework that consists of (1) systematic design space exploration and a multi-objective optimization formulation to minimize the likelihood of failure causes (such as fatigue and wear) and environmental footprint, (2) topology optimization to further reduce material usage without significantly affecting the load-carrying capability of the product, and (3) post-topology optimization design verification to ensure the proposed design satisfies all design constraints. The environmental impact can be assessed at varying comprehensiveness levels (e.g., design and manufacturing phase, use phase) and in terms of carbon or GHG emission, energy use, and waste generation. Because the novel design framework predominantly adjusted the geometry, we focused on mass-based change and energy savings due to sustained remanufacturability. The multi-objective optimization formulation in the first step results in a Pareto optimal set of possible design solutions that the designer can use for the second step. We demonstrate the utility of this framework through a case study of an engine cylinder head subjected to thermo-mechanical loads, where we find that about 5% of the product mass can be conserved with only about a 3% increase in surface area that has a fatigue life less than 10,000 cycles.

Characterization, generative design, and fabrication of a carbon fiber-reinforced industrial robot gripper via additive manufacturing

Robot grippers are crucial components across various industrial applications, requiring special design and production for obtaining the optimal performance. Conventional plastic injection moulding techniques fall short in achieving the specificity needed for these grippers. To address this challenge, current paper focuses on developing a robot gripper using carbon fiber-reinforced polyamide with a next-generation composite filament and employing the innovative Generative Design technique. In the work, we began by characterizing and optimizing the composite material specifications. Then, the tensile strength and fracture mechanics of standard samples based on printing parameters, applying Taguchi experimental design for optimization were evaluated. Analysis of Variance (ANOVA) was used for factor analysis to fine-tune the process. Using the Generative Design technique, we determined optimal geometries, which were then fabricated through Fused Deposition Modeling (FDM). As a result, the optimization efforts led to significant improvements i.e., tensile strength increased from 103.2 to 116 MPa, and the elasticity modulus from 8386 to 8990 MPa. In practical industrial applications, we achieved a reduction in material weight from 14 to 4 g, lowered production costs from $5.16 to $1.50, and cut production time from 58 to 28 min. This study presents a validated method for developing industrial products with reduced material usage and costs, promoting sustainable production practices.

Optimal performance of silicon nanowire solar cells under low sunlight concentration and their integration as bottom cells in III–V multijunction systems

Nanostructured silicon solar cells are designed to minimize costs through reduced material usage while enhancing power conversion efficiency via superior light trapping and shorter charge separation distances compared to traditional planar cells. This study identifies the optimal conditions for nanoimprinted silicon nanowire (SiNW) solar cells to achieve maximum efficiency under low sunlight concentration and evaluates their performance as bottom cells in III–V multijunction solar cell systems. The findings indicate that the SiNW solar cell reaches its peak performance at a concentration factor of 7.5 suns and a temperature of 40°C or lower. Specifically, the absolute conversion efficiency under these conditions is 1.05% higher than that under unconcentrated light. Compared to a planar silicon solar cell under identical conditions, the SiNW solar cell exhibits a 3.75% increase in conversion efficiency. Additionally, the SiNW single-junction solar cell, when integrated in series with a commercial lattice-matched InGaP/GaAs dual-junction solar cell, was tested under unconcentrated sunlight, specifically at one-sun, global air mass 1.5 condition, to assess its viability in one-sun multi-junction solar cell applications. The results suggest that a III–V upper subcell with a smaller active area than that of the SiNW subcell is optimal for maximizing current production, which is favorable to the cost reduction of the device. This hybrid configuration is particularly advantageous for terrestrial applications, such as electric vehicles, which demand lightweight, high-performance multijunction solar cell devices. Although the weight reduction of the characterized SiNW solar cell with a full silicon substrate compared to its planar solar cell counterpart is 1.8%, recommendations to increase this reduction to as much as 64.5% are discussed to conclude this paper.

Impact of lattice structure on compressive performance and strength to weight ratio in continuous stereolithography

Lattice structures have emerged as a creative solution in additive manufacturing to achieve lightweight structures. Lattices offer the capability to reduce material usage, production costs, and weight while maintaining the structural integrity of a part. Due to its rise in popularity and excellent properties, lattice structures have been used in many applications, including but not limited to aerospace, bioengineering, and acoustics. This study aimed to explore the performance of different types of lattices on 3D additive manufactured parts by varying the type of unit cell. The three unit cells that were compared are body-centered cubic (BCC), face-centered cubic (FCC), and Fluorite. The lattice’s strength-to-weight ratio of different lattice unit cells when subjected to compression forces was evaluated. BCC and FCC have had considerable research while Fluorite has had far less research. This study aims to contribute new knowledge on the less studied Fluorite unit cell. The selected lattice structures were printed using continuous stereolithography (CSLA). This 3D printing process utilizes a photopolymerization reaction to solidify liquid resin layer by layer. Through this study, Fluorite demonstrated the highest strength-to-weight ratio among the three lattice structures examined, averaging 19,377 Nm/kg over five samples. Its potential for applications requiring high strength requirements is highlighted by this finding. Alternatively, BCC lattice structures had the weakest strength-to-weight ratio but exhibited remarkable structural resilience to deformation. The BCC lattice structures showed a more significant deformation before failure. Fluorite lattice structures are more suitable for high-strength applications, while BCC lattice structures can be used where high strength is not a primary parameter. This research aimed to determine the optimal lattice unit cell to implement in future choices in additive manufacturing applications.

Structural behaviour of hollow core reinforced concrete (HCRC) short column under static load

The high strength-to-weight and low self-weight ratio of Hollow Core Reinforced Concrete (HCRC) short columns have made them a popular choice for application in construction. Nevertheless, little is known about how HCRC short columns behave when subjected to static loads. This is because HCRC short columns are a relatively recent type of structural member, and there has been little research into how well they behave when subjected to static loads. Given that HCRC short columns are made of composite material, it poses one of the difficulties in understanding their behaviour when subjected to static load. The complex relationship between the steel reinforcement and concrete core potentially affects the column’s ability to support loads and failure more. The purpose of this research is to evaluate their failure mechanisms and assess the structural performance under static load. Finite element models with different configuration are modelled which can simulate the complex behaviour of reinforced concrete structures under static load. This study found that Square Hollow Core (SHC) and Circular Hollow Core (CHC) are known as the most affected columns in terms of displacement compared to Rectangular Hollow Core (RHC). Stress was critically found at the top section of the column and it reduced towards lower section. The finding is able to optimize load-bearing efficiency, reduce material usage, enhance stability, improve resistance, and be proposed as modern structural applications.

Design and performance assessment of a solar photovoltaic panel integrated with heat pipes and bio-based phase change material: A hybrid passive cooling strategy

This study investigates the effectiveness of an indirect passive cooling solution for photovoltaic (PV) panels using flattened heat pipes (FHPs) and phase change material (PCM). An innovative passive cooling design is proposed to cool a PV panel using multiple FHPs with a thin graphite sheet between the PV panel and the FHPs. Five experimental cases are examined under varying heat flux loads. Case O serves as the baseline with no cooling system, while Cases 1 to 4 feature different configurations of FHPs and aluminum sheets, with PCM heat sinks added in Cases 2 and 4. The investigation focuses on temperature profiles, temperature reductions, and final temperatures of the PV panel, especially at the end of a 4-hour experimental period when the PCM is fully melted. The results show significant temperature reductions in Case 1 compared to the baseline, with further improvement in Case 2 due to the PCM heat sink. Temperature reductions in Cases 2 and 4 are consistently higher than in Cases 1 and 3, demonstrating the enhanced cooling potential of PCM. Case 4 achieves the highest temperature reduction of 37.0 °C, followed by Case 2 with 34.9 °C under a radiative heat flux of 1000 W/m2. Using 4 FHPs (Cases 1 and 2) is economically justified, offering comparable cooling performance to 8 FHPs (Cases 3 and 4), thus ensuring cost-effectiveness and reducing material usage by over 50 %. A maximum enhancement in PV electrical efficiency of 17.3 % is achieved in Case 2 during PCM phase change with a radiative heat flux of 1000 W/m2.

Surface wave isolation by variable depth infilled trenches

Excessive environmental vibrations generated by urban traffic pose adverse effects on nearby structures and residents. These vibrations are predominantly carried by surface waves, which are localized within the surface layer of soil. The isolation of surface waves through the embedding of periodic wave barriers in soils between the source and the receiver has gained significant attention in recent years. In this paper, a novel approach is proposed for isolating surface waves induced by urban traffic through the use of variable depth infilled trenches. This innovative design not only achieves efficient surface wave isolation but also minimizes the consumption of structural materials. Based on the measured dominant frequency range of rail transit and the available soil parameters, variable depth infilled trenches are designed with suitable dimensions. The eigenvalue equation is solved using the finite element method to derive the dispersion relations and bandgap of identical regularly spaced trenches. To study the efficacy of the proposed structure, a finite element model of the soil-infilled trench system is developed using COMSOL. The mechanism underlying the isolation of surface wave is elucidated, and the effect of variable angle α on the isolation efficiency within 40–50 Hz η40−50Hz of surface waves is studied. The results of this study reveal that for variable angle α of 15°, the surface wave isolation efficiency within 40–50 Hz η40−50Hz is 90.9 % and 92.5 % for uniformly increasing depth infilled trenches and uniformly decreasing depth infilled trenches, respectively. Although the surface wave isolation efficiencies predicted for the variable depth infilled trench arrangements are only 93.8 % and 95.5 % of those predicted for the regularly spaced identical infilled trenches, the variable depth arrangements result in a remarkable 34 % reduction in material usage. These findings highlight the potential of the proposed variable depth infilled trenches as a cost-effective and efficient solution for surface wave isolation.

Durability Analysis and Cost Efficiency of RCC Beams Using Conventional Concrete Versus Bubble Deck Technique: A Statistical Investigation

A crucial tectonic component in the building of houses and other structures are beams. The structural dead load is substantially reduced by virtually removing the non-structural concrete from the beam's core. A bubble beam is one in which various sized and shaped spheres are used in place of the beam's core. There are benefits to factory-made materials and components, regulated environments, on- and off-site finishing, hollow Bubble Deck technology, and regulated settings. Numerous advantages are offered, such as reduced total expenses, reduced material usage, enhanced structural effectiveness, expedited building, and eco-friendliness. Instead of using concrete, the midsection of the beam in this project is constructed from high density polyethylene balls the content that appears most regularly.

Enhancing the engineering performance of lightweight limestone calcined clay cement concrete using used engine oil as a foam stabilizer

Lightweight foam concrete is an appealing thermal insulation material with great potential for decarbonizing the building sector, given that its superior thermal insulation and reduced material usage promote energy-efficient and low-carbon constructions. However, traditional foam concrete largely depends on carbon-intensive ordinary Portland cement (OPC) and costly foam stabilizers, e.g., nanomaterials. To address these issues, this study developed an eco-friendly foam concrete formula incorporating limestone calcined clay cement as a low-carbon cement substitute and used engine oil (UEO) as a foam stabilizer. The viability of this formula was confirmed by assessing foam stability performance of UEO-enhanced foam and crucial engineering performance – thermal conductivity and compressive strength – of foam concrete. Experiments demonstrate that 1 % UEO notably boosts foam stability, with prolonged stable time by 75 % and enhanced remaining foam fraction by 43 %. Additionally, 1 % UEO-containing foam concrete exhibits superior compressive strength of 3.2 MPa and reduced thermal conductivity of 0.162 W⋅m-1K-1, outperforming foam concrete without UEO. The mechanisms of macroscopic performance changes were revealed through scanning electron microscopy (SEM), which disclosed a uniformly established UEO-enhanced pore system and UEO-driven hydration process as the microscale origins. These findings provide waste-enhanced foam stabilizers and present an environmentally appealing alternative to traditional foam concrete, with implications for clean waste management and building decarbonization.

Shell stand: Stable thin shell models for 3D fabrication

A thin shell model refers to a surface or structure, where the object’s thickness is considered negligible. In the context of 3D printing, thin shell models are characterized by having lightweight, hollow structures, and reduced material usage. Their versatility and visual appeal make them popular in various fields, such as cloth simulation, character skinning, and for thin-walled structures like leaves, paper, or metal sheets. Nevertheless, optimization of thin shell models without external support remains a challenge due to their minimal interior operational space. For the same reasons, hollowing methods are also unsuitable for this task. In fact, thin shell modulation methods are required to preserve the visual appearance of a two-sided surface which further constrain the problem space. In this paper, we introduce a new visual disparity metric tailored for shell models, integrating local details and global shape attributes in terms of visual perception. Our method modulates thin shell models using global deformations and local thickening while accounting for visual saliency, stability, and structural integrity. Thereby, thin shell models such as bas-reliefs, hollow shapes, and cloth can be stabilized to stand in arbitrary orientations, making them ideal for 3D printing.

Progress toward the Definition of X-ray Computed Tomography Accuracy in the Characterization of Polymer-Based Lattice Structures.

Lattice structures have become an innovative solution for the improvement of part design, as they are able to substitute solid regions, maintain mechanical capabilities, and reduce material usage; however, dimensional quality control of these geometries is challenging. X-ray computed tomography (XCT) is the most suitable non-destructive metrological technique as it is capable of characterizing internal features and hidden elements. Uncertainty estimation of XCT is still in development, and studies typically use high-resolution calibrated devices such as focal variation microscopes (FVMs) as a reference, focusing on certain parts of the lattice but not the whole structure. In this paper, an estimation of the accuracy of XCT evaluation of a complete lattice structure in comparison to a higher-resolution reference device (FVM) is presented. Experimental measurements are taken on ad hoc designed test objects manufactured in polyamide 12 (PA12) using selective laser sintering (SLS), optimized for the evaluation on both instruments using different cubic-based lattice typologies. The results confirm higher precision on XCT evaluation in both qualitative and quantitative analysis. Even with a lower resolution, XCT is able to characterize details of the surface such as re-entrant features; as well, standard deviations and uncertainties in strut diameter evaluation remain more stable in all cells in XCT, identifying on the other hand reconstruction problems on FVM measurements. Moreover, it is shown that, using XCT, no additional evaluation errors were found in inner cells, suggesting that the measurement of external elements could be representative of the whole structure for metrological purposes.

Lightweight Designs and Improving the Load-Bearing Capacity of Structures by the Method of Aggregation

Lightweight Designs and Improving the Load-Bearing Capacity of Structures by the Method of Aggregation

Porcospino Flex: A Bio-Inspired Single-Track Robot with a 3D-Printed, Flexible, Compliant Vertebral Column

This paper is focused on the design and development of the Porcospino Flex, a single-track robot inspired by nature and featuring a meta-material structure. In the earlier version of the Porcospino, the main body was composed of a chain of vertebrae and two end sections linked by flexible joints, but the excessive use of materials in 3D printing and the resulting weight of the robot posed challenges, ultimately leading to a decrease in its overall efficiency and performance. The Porcospino Flex is manufactured through the fused deposition modeling process using acrylonitrile butadiene styrene and thermoplastic polyurethane, featuring a singular meta-material structure vertebral column. The adoption of a lattice structure in the main body of the Porcospino Flex leads to a substantial increase in performance, reducing its weight from 4200 g to 3600 g. Furthermore, the decrease in weight leads to a reduction in material usage and waste, making a substantial contribution to the sustainability of the robot. The discussion focuses on the testing results of the Porcospino Flex prototype, highlighting the enhancements observed compared to its prior version.