Purpose The purpose of this paper is to study the feasibility of the fabrication of circle arc curved-layered structures via conventional fused deposition modeling (FDM) with three-axis machines and to identify the main structural parameters that have an influence on their mechanical properties. Design/methodology/approach Customized G-codes were generated via a script developed in MATLAB. The G-codes contain nozzle trajectories with displacements in the three axes simultaneously. Using these, the samples were fabricated with different porosities, and their influence on the mechanical responses evaluated via tensile testing. The load-displacement curves were analyzed to understand the structure-property relationship. Findings Circled arc curved-layered structures were successfully fabricated with conventional three-axis FDM machines. The response of these curved lattice structures under tensile loads was mapped to three main stages and deformation mechanisms, namely, straightening, stretching and fracture. The micro-structure formed by the transverse filaments affect the first stage significantly and the other two minimally. The main parameters that affect the structural response were found to be the transverse filaments, as these could behave as hinges, allowing the slide/rotation of adjacent layers and making the structure more shear sensitive. Research limitations/implications This paper was restricted to arc-curved samples fabricated with conventional three-axis FDM machines. Originality/value The FDM fabrication of curved-structures with controlled porosity and their relation to the resulting mechanical properties is presented here for the first time. The study of curved-lattice structures is of great relevance in various areas, such as biomedical, architecture and aerospace.

Novel rationally designed structured materials (SMs) exhibit unconventional mechanical properties that cannot be found in common materials. Although most microarchitectures of the developed SMs are based on regular unit cell tessellation design, few studies have explored the potential of fractal geometry as a design tool for creating new SMs. A novel strategy for creating fractal-like aperiodic SMs based on Hilbert self-filling fractal curves synthetization is presented here. Families of continuous Hilbert structured cubes derived from two separate Hilbert curve iterations at three different matching relative densities were obtained, additionally, a method to decompose the Hilbert curve to obtain non-continuous Hilbert structured cubes is proposed. To obtain a broad overview of their mechanical response, samples were manufactured out of thermoplastic polyurethane via fused filament fabrication and tested under compression. An apparent model of elasticity has been proposed to classify their mechanical performance under low and high strain. Results showed that relative stiffness, energy absorption and deformation could be tuned by adjusting parameters of the Hilbert structured cubes. By iterating the Hilbert curve from n = 4 to n = 5, a 51% increase in stiffness was obtained. A significant increment of 82% and 148% on stiffness was observed on non-continuous Hilbert structured cubes for the first and second orders, respectively; besides, energy absorption capabilities and great shape recovery were observed.