Metamaterials from the Deep: Optimized Mechano-Fluidic Materials Inspired by Deep-Sea Sponges

Multifunctional materials that balance mechanical resilience and fluid dynamic efficiency are increasingly critical in engineering applications, yet the synergistic optimization of these properties remains a challenge due to inherent trade-offs, computational and experimental expense, and the complexity of high-dimensional design spaces. Inspired by the hierarchical skeleton of the deep-sea sponge Euplectella aspergillum , which shows distinct mechanical and fluidic characteristics, this study presents a framework that integrates high-fidelity Finite Element Analysis for mechanics, Volume of Fluid methods for flow simulations, and multi-objective Bayesian optimization. Using high-performance computing, our approach efficiently explores complex design spaces to identify Pareto-optimal solutions. Optimized lattices showed an average 140% improvement in critical buckling force across a range of volume fractions relative to baseline designs, along with significant reductions in drag, lift, and vortex shedding, achieved with porosities as low as 5%. Fabricated using stereolithography and validated through mechanical compression tests and stereo particle image velocimetry, experimental results align with computational simulations. By achieving simultaneous optimization of mechanical and fluidic performance, this research establishes a methodology for designing lightweight, high-performance materials with applications in aerospace, civil engineering, and energy systems.