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This study aims to focus on a short review on recent results dealing with the mechanical modelling and experimental characterization of a novel class of tensegrity structures, named class θ = 1 tensegrity prisms. The examined structures exhibit six bars connected by two disjoint sets of strings.

First, the self-equilibrium problem of tensegrity θ = 1 prisms is numerically investigated for varying values of two aspect parameters and, next, their prestress stability is studied. The mechanical behavior of the examined structures in the large displacements regime under uniform compression loading is also numerically computed through a path-following procedure. Finally, the predicted constitutive response is validated through experimental tests.

The presented results highlight that the examined structures exhibit a large number of infinitesimal mechanisms from the freestanding configuration, and reveal that they exhibit tunable elastic response switching from stiffening to softening.

This multi-faceted elastic response is in agreement with previous literature results on the elastic response of minimal tensegrity prism, and suggests that such units can be usefully used as non-linear springs in next-generation tensegrity metamaterials.

Laser sintering of polyamide lattice-based lightweight fairing components for subsequent racetrack testing requires a high quality and a reliable design. Hence, the purpose of this study was to develop a design methodology for such additively manufactured prototypes, considering efficient generation and structural simulation of boundary conformal non-periodic lattices, optimization of production parameters as well as experimental validation.

Multi-curved, sandwich structure-based demonstrators were designed, simulated and experimentally tested with boundary conformal lattice cells. The demonstrator’s non-periodic lattice cells were simplified by forward homogenization processes. To represent the stiffness of the top and bottom face sheet, constant isotropic and mapped transversely isotropic simulation approaches were compared. The dimensional accuracy of lattice cells and demonstrators were measured with a gauge caliper and a three-dimensional scanning system. The optimized process parameters for lattice structures were transferred onto a large volume laser sintering system. The stiffness of each finite element analysis was verified by an experimental test setup including a digital image correlation system.

The stiffness prediction of the mapped was superior to the constant approach and underestimated the test results with −6.5%. Using a full scale fairing the applicability of the development process was successfully demonstrated.

The design approach elaborated in this research covers aspects from efficient geometry generation over structural simulation to experimental testing of produced parts. This methodology is not only relevant in the context of motor sports but is transferrable for all additively manufactured large scale components featuring a complex lattice sub-structure and is, therefore, relevant across industries.