Breaking better: Imperfections increase fracture resistance in architected lattices

Architected materials offer unique opportunities to tailor fracture properties through local structural modifications. In this study, we investigate how the failure of architected materials with triangular lattice topology is affected by the removal of individual struts, which represent well-controlled and localized imperfections. Using a combination of macroscopic mechanical testing and digital image correlation (DIC), we analyze both global response and local crack propagation. We observe that the designed imperfections do not alter the failure initiation site nor the peak tensile load but significantly increase the work to failure. DIC-based tracking reveals that this increase correlates with deviations in the crack path and may also involve mechanisms such as crack bridging or temporary pinning near defects. These results demonstrate that small, well-characterized imperfections, when properly mastered, can be harnessed to improve failure resistance and expand the design space of architected materials beyond regular, periodic structures.