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All sourcesNASA NTRSDOE OSTI
DOE OSTI2025

Role of Intersections in Fracture Connectivity

Networks of intersecting fractures often provide the flow paths through subsurface reservoirs. Assessing network connectivity is challenging because fracture intersections compose a vanishingly small fraction of the network void volume. In this paper, motivated by 3D X-ray imaging of the simplest element of fracture network, that is, two orthogonal fractures, we perform a percolation and finite-size scaling analysis to study the connectivity provided by fracture intersections. The conditions when an intersection enhances connectivity across a sample depend on spatial correlations in the fracture aperture distributions, on the stress state, and on the direction of flow. Here we consider three flow directions: (a) across intersections, (b) parallel to intersections and (c) around corners. For (a), intersections provide minimal enhancement of connectivity because they contribute little additional void area. For (b), intersections increase the probability of a connected path near threshold by enabling 3D connected pathways that are not possible in parallel fractures. Flow around corners, (c), is fundamentally the result of the intersection connecting two fractures in series and spatial correlations are broken around corners, suppressing the connectivity relative to (a). When the connected fractures are stressed equally, a joint percolation threshold emerges that continues to have scale invariance. However, when the fractures are stressed unequally, the system has mixed percolation without clearly defined percolation thresholds. In all cases, percolation probabilities are found to be scale dependent which has important consequences for the connectivity of larger fracture networks composed of the fundamental element studied here.

02 PETROLEUM↗
DOE OSTI2024

Numerical investigation of multiphase flow through self-affine rough fractures

Multiphase flow through fractures has great significance in subsurface energy recovery and gas storage applications. Different fracture and flow properties affect flow through a fracture which is difficult to control in laboratory experiments. Here, we perform lattice Boltzmann simulations in an ensemble of synthetically generated fractures. Drainage simulations are performed at different capillary numbers, wettability, and viscosity ratios. We track the invading front and quantify breakthrough saturations and show that roughness and wettability have a strong effect on fluid invasion through a complex fracture. Invading a more viscous fluid results in more stable displacement regardless of the capillary number while at very low capillary numbers, fluid migration is dependent on the inherent structure of the fracture. We develop a fluid displacement phase diagram in a single rough fracture and compare our results from that in the literature. Finally, we extend the phase diagrams across multiple fractures and demonstrate the importance of natural fracture features of roughness and wettability in identifying stable versus unstable displacement regimes during multiphase flow through rough fractures. Our work presents an end-to-end numerical pathway for testing on experimental data and expanding numerical data sets for testing combinations of different physical phenomenon and make valuable predictions on fluid flow through rough fractures.

02 PETROLEUM↗
DOE OSTI2024

Altered post-fracture systemic bone loss in a mouse model of osteocyte dysfunction

Femur fracture leads to loss of bone at uninjured skeletal sites, which may increase risk of subsequent fracture. Osteocytes, the most abundant bone cells, can directly resorb bone matrix and regulate osteoclast and osteoblast activity, but their role in systemic bone loss after fracture remains poorly understood. In this study we used a transgenic (TG+) mouse model that overexpresses human B-cell lymphoma 2 (BCL-2) in osteoblasts and osteocytes. This causes enhanced osteoblast proliferation, followed by disruption in lacunar-canalicular connectivity and massive osteocyte death by 10 wk of age. We hypothesized that reduced viable osteocyte density would decrease the magnitude of systemic bone loss after femur fracture, reduce perilacunar remodeling, and alter callus formation. Bone remodeling was assessed using serum biomarkers of bone formation and resorption at 5 d post-fracture. We used micro-computed tomography, high resolution x-ray microscopy, mechanical testing, and Raman spectroscopy to quantify the magnitude of systemic bone loss, as well as changes in osteocyte lacunar volume, bone strength, and bone composition 2 wk post-fracture. Fracture was associated with a reduction in circulating markers of bone resorption in non-transgenic (TG-) animals. TG+ mice exhibited high bone mass in the limbs, greater cortical elastic modulus and reduced post-yield displacement. After fracture, TG+ mice lost less trabecular bone than TG- mice, but conversely TG+ mice exhibited trends toward a lower yield point and reduced femoral cortical thickness after fracture, though these were not statistically significant. Lacunar density was greater in TG+ mice, but fracture did not alter lacunar volume in TG+ or TG- mice. These findings suggest that osteocytes potentially play a significant role in the post-traumatic systemic response to fracture, though the effects differ between trabecular and cortical bone.

60 APPLIED LIFE SCIENCES↗
DOE OSTI2024

Utah FORGE: 2024 Discrete Fracture Network Model Data

The Utah FORGE 2024 Discrete Fracture Network (DFN) Model dataset provides a set of files representing discrete fracture network modeling for the FORGE site near Milford, Utah. The dataset includes four distinct DFN model file sets, each corresponding to different time frames and modeling approaches in 2024. These models characterize both natural and induced fractures in the geothermal reservoir, which consists of crystalline granitic and metamorphic rock approximately 8,000 feet below the ground surface. The dataset includes a reference DFN model from February 2024 that incorporates planar fractures and well trajectories, as well as upscaled permeability, porosity, compressibility, and storage values on specified grids. Additionally, there are models based on new microseismic (MEQ) data from May and July 2024, including fracture planes fitted to the latest MEQ catalog datasets, tensile fractures from hydraulic stimulation, and an alternative connected DFN for modeling purposes. Coordinate data is provided in both global and local frames, with detailed instructions on the transformations used to align with principal stress orientations. The dataset also includes notes and calculation files for estimating fracture sizes and differences between various fracture sets. There are subfolders for Global Coordinates and Local Coordinates. To move from the global to the local coordinate frame, fractures and wells were a) rotated 20 degrees counterclockwise looking down about the global point (335376.400482041, 4263189.99998761, 250.093546450195) to better align with the principal stresses; and b) translated by (-335408.68, -4263010.9, 1150). Upscaled permeability values using the _XYZ suffix show directions with respect to the global XYZ coordinate frame, while those using the _IJK suffix are aligned with local coordinate frame.

15 GEOTHERMAL ENERGY↗
DOE OSTI2025

Using Radiogenic Noble Gas Nuclides to Identify and Characterize Rock Fracturing

Abstract Fracture‐released radiogenic noble gas nuclides are used to identify locations and constrain the volume of new fracture creation during subsurface detonations. Real‐time, in situ noble gases and reactive gases were monitored using a field‐deployed mass spectrometer and automated sampling system in a multilevel borehole array. Released gases were measured after two different detonations having distinct energy, pressure, and gas volume characteristics. Explosive‐derived gases (N 2 O, CO 2 ) and excess radiogenic 4 He and 40 Ar above atmospheric background are used to identify locations of gas transport and new fracture creation after each detonation. Fracture‐released radiogenic 4 He is used to constrain the volume of newly created fractures with a model of helium release from fracturing. Explosive by‐product gas was observed in multiple locations both near and distal to the shot locations for both detonations. Radiogenic 4 He and 40 Ar release from rock damage was observed in locations near the detonation after the second, more powerful detonation. Observed 4 He response is consistent with a model of diffusive release from newly created fractures. Volume of new fractures estimated from the 4 He release ranges from 1 to 5 m 2 with apertures ranging from 0.1 to 1 m. Our results provide evidence that radiogenic noble gases released during fracture creation can be identified at the field scale in real time and used to identify timing and location of fracture creation during deformation events. This technique could be useful in subsurface science and engineering problems where the location and amount of newly created rock fracturing is of interest including fault rupture, mine safety, subsurface detonation monitoring and reservoir stimulation.

58 GEOSCIENCES↗
DOE OSTI2026

Sequential Fracture Activation and Stress Evolution During EGS Stimulation at Utah FORGE Revealed by Waveform Cross‐Correlation

Mapping fracture networks in Enhanced Geothermal Systems (EGS) is essential for optimizing reservoir performance, yet complex fracture evolution during stimulation remains difficult to resolve. This study examines the evolution of microseismicity and fracture networks during stage 3 of the 2022 EGS stimulation at the Utah Frontier Observatory for Research in Geothermal Energy site. We map the fracture network represented by 20 clusters of seismic events identified by waveform similarities with cross-correlation. We characterize their geometric properties such as strike, dip, length, and width, and analyze the time evolution of activated fractures. The results reveal a systematic fracture evolution: early activation of pre-existing natural fractures, complex network development during peak injection, and continued activation of less favorably oriented fractures post-injection. Magnitude calibration using the Principal Component Analysis of cross-correlated waveforms improves relative amplitude measurements, refining estimations of the Gutenberg-Richter b-values with spatial variations in b-values suggesting stress re-distribution across the stimulated area. Analysis of the stress state of selected fractures further shows that fractures requiring higher excess pore pressure primarily activate at the end of injection and post-injection, highlighting stress transfer due to pore pressure as a dominant triggering mechanism. These findings provide insights into fracture propagation, stress evolution, and seismic hazard assessment in EGS reservoirs.

Asirifi, Richard [Texas A & M Univ., College Stati↗
DOE OSTI2024

Crack opening calculation in phase-field modeling of fluid-filled fracture: A robust and efficient strain-based method

The phase-field method has become popular for the numerical modeling of fluid-filled fractures, thanks to its ability to represent complex fracture geometry without algorithms. However, the algorithm-free representation of fracture geometry poses a significant challenge in calculating the crack opening (aperture) of phase-field fracture, which governs the fracture permeability and hence the overall hydromechanical behavior. Although several approaches have been devised to compute the crack opening of phase-field fracture, they require a sophisticated algorithm for post-processing the phase-field values or an additional parameter sensitive to the element size and alignment. Here, we develop a novel method for calculating the crack opening of fluid-filled phase-field fracture, which enables one to obtain the crack opening without additional algorithms or parameters. Here we transform the displacement-jump-based kinematics of a fracture into a continuous strain-based version, insert it into a force balance equation on the fracture, and apply the phase-field approximation. Through this procedure, we obtain a simple equation for the crack opening which can be calculated with quantities at individual material points. We verify the proposed method with analytical and numerical solutions obtained based on discrete representations of fractures, demonstrating its capability to calculate the crack opening regardless of the element size or alignment.

58 GEOSCIENCES↗
DOE OSTI2024

A Thermo‐Flow‐Mechanics‐Fracture Model Coupling a Phase‐Field Interface Approach and Thermo‐Fluid‐Structure Interaction

This work proposes a novel approach for coupling non-isothermal fluid dynamics with fracture mechanics to capture thermal effects within fluid-filled fractures accurately. This method addresses critical aspects of calculating fracture width in enhanced geothermal systems, where the temperature effects of fractures are crucial. The proposed algorithm features an iterative coupling between an interface-capturing phase-field fracture method and interface-tracking thermo-fluid-structure interaction using arbitrary Lagrangian–Eulerian coordinates. We use a phase-field approach to represent fractures and reconstruct the geometry to frame a thermo-fluid-structure interaction problem, resulting in pressure and temperature fields that drive fracture propagation. We developed a novel phase-field interface model accounting for thermal effects, enabling the coupling of quantities specific to the fluid-filled fracture with the phase-field model through the interface between the fracture and the intact solid domain. We provide several numerical examples to demonstrate the capabilities of the proposed algorithm. In particular, we analyze mesh convergence of our phase-field interface model, investigate the effects of temperature on crack width and volume in a static regime, and highlight the method's potential for modeling slowly propagating fractures.

fracture↗
DOE OSTI2026

Predicting fracture behavior in single crystal nickel using a coupled crystal plasticity phase field damage approach

Understanding the fracture behavior of single crystal metals is critical for predicting material performance under mechanical loading. Here, in this study, we investigate the fracture characteristics of single crystal nickel tensile bars using a crystal plasticity coupled phase field damage (CP-PFD) model. Experimental tensile tests were conducted on 15 specimens spanning five crystallographic orientations and three thickness variants per orientation. The results revealed two distinct fracture modes: brittle fractures with 45-degree angled surfaces and ductile fractures characterized by significant necking. The CP-PFD model successfully replicated these fracture behaviors, demonstrating strong agreement with experimental observations. The model effectively predicted the strain at which necking and fracture occurred, as well as the orientation-dependent fracture mechanisms. By comparing experimental and simulated fracture surfaces, we establish the CP-PFD model as a robust tool for predicting single crystal behavior and damage evolution. This work provides insight into the microstructural dependence of fracture behavior and establishes a predictive framework for modeling orientation-dependent damage evolution in single-crystal nickel.

Crystal plasticity↗
DOE OSTI2025

Understanding Fracture Aperture and Permeability Evolution due to Carbonate Mineralization Utilizing 3D Printing

Caprock formations are a crucial part of subsurface-engineered systems. Composed largely of shale, caprocks act as natural barriers that prevent the upward migration of fluids, thereby ensuring the containment of stored substances in subsurface formations. Fractures in these formations are potential leakage pathways for stored fluids. Mineral precipitation reactions in these fractures, particularly calcite, can significantly restrict the fluid permeability, reducing leakage potential. However, predictive capabilities of mineral precipitation in fractures and associated permeability evolution are limited due to a lack of fundamental understanding of such reactions in natural samples, complicated by mineral heterogeneity and the complexity of the fracture structure. In this study, 3D-printed fracture samples are used to understand the impact of carbonate mineralization on fracture aperture and permeability evolution. Samples were printed using a digital light processing (DLP) 3D printer and commercial liquid resin. Calcite precipitation was first tested on printed 2D films before conducting plug flow column experiments aimed to understand fracture permeability changes due to mineral precipitation. Contact angle measurement and Fourier transform infrared (FTIR) spectroscopy on printed 2D films show evidence of a substantial amount of surface energy for calcite nucleation and precipitation. Surface topography analysis of printed fractured surfaces reveals comparable values, highlighting the high replicability of the printed samples. During the column experiments, the permeability reduces exponentially due to a decrease in fracture aperture. Reductions in fracture aperture estimated from effluent concentration and 3D X-ray computed tomography (CT) show comparable results. Moreover, 3D X-ray CT images suggest the impact of local flow velocities on precipitation. The insights gained from this research contribute to a deeper understanding of the permeability evolution due to carbonate mineralization in caprock formations.

3D printing↗
DOE OSTI2024

Fracture Characterization Via AI‐Assisted Analysis of Temperature Logs

Abstract Fractures control fluid flow, mass transport, and heat transfer in a geothermal reservoir. This makes accurate characterization of fracture networks a prerequisite for optimal design and control of a reservoir's exploitation. We develop a deep‐learning procedure to identify fracture locations via interpretation of temporally and spatially continuous downhole temperature measurements. A long short‐term memory fully convolutional network (LSTM‐FCN) is used both to capture long‐term dependencies in sequential temperature data and to distill local features around fractures. A wellbore and fractured‐reservoir thermal model is established to generate temperature data for network training. The trained LSTM‐FCN exhibits a unique ability to detect multiple fractures intersecting a borehole. We use the LSTM‐FCN algorithm to evaluate the effectiveness of different‐stage wellbore temperature measurements on fracture detection in a complex fractured system. Our experiments reveal that the use of various‐stage temperature information as an input feature set improves the robustness of fracture detection to noise interference. This study indicates the practical feasibility of obtaining accurate fracture‐network reconstructions from temperature signals, at reasonable computational cost.

Yang, Xiaoyu↗
DOE OSTI2025

Utah FORGE: Well 16B(78)-32 Drill Core Fracture Analysis Images and Data

This dataset contains drilling core data from well 16B(78)-32, including PDF documents with flattened core images annotated by feature type and core interval, as well as spreadsheets detailing feature morphologies by depth, planar feature measurements, and planar feature orientations rotated to in situ conditions. Core was recovered from three intervals, one per stimulation stage, in the crystalline rocks affected by the stimulation of well 16A(78)-32. Seven core runs were conducted, yielding 135.8 feet of recovered core. Features in the core were categorized into planar fractures, semi-planar fractures, unbroken mineralized fractures, rough fractures, curviplanar fractures, concave-convex surfaces, and planar compositional features such as mylonite or dike-like structures. Planar features were measured while the core was positioned horizontally, with the core axis aligned to a downhole azimuth of 42 degrees. Planar core measurements from stimulations 2 and 3 that could be confidently correlated with FMI data were rotated to in situ orientations. This was done by rotating the planes along vertical and horizontal axes to match the azimuth and inclination data recorded in the directional survey of well 16B(78)-32, as well as applying an axial rotation to resemble the fracture orientations observed in the FMI log at corresponding depths. Coherent sets of planar fracture measurements were made by aligning the core within each 3-foot section of the dissected core barrel, and between adjacent 3-foot sections within a core run by matching rock fabrics, saw cuts and/or tool marks. Where coherent fracture measurements could not be made within a core run, data sets are denoted by a subscript (i.e. 2-Ta and 2-Tb both come from tangent core run number 2).

15 GEOTHERMAL ENERGY↗
DOE OSTI2024

Relative permeabilities for two-phase flow through wellbore cement fractures

Multiple fluids are likely to exist in fractures and flow paths associated with leaky wellbores, including liquids (e.g., crude oil) and gases (e.g., gas exsolved from liquid). These fluids occupy and move through different portions of the pore spaces within the fractures depending on many factors, including fluid properties, fracture size, and the amount of the different fluids. Upward leakage of any phase, through the fracture, can contaminate water-bearing formations, create hazardous surface conditions, and compromise the functionality of the wellbore. Early signs of wellbore leaks may be expressed by anomalous pressure behavior at surface monitoring points on cavern storage wells. These pressure anomalies are difficult to interpret, necessitating knowledge of the factors that affect the multiphase flow in fractures and porous media. These parameters are critical to modeling multiphase flow in fractures. This insight can guide further diagnosis and maximize leak remediation. Here, our study focuses on the relationship of the liquid–gas relative permeabilities for representative variable-aperture wellbore cement fracture. To obtain the relative permeability of each phase, two-phase flow tests were conducted where both fluids were flowing simultaneously through a fractured wellbore cement specimen under a range of factors, namely (1) aperture size, (2) capillary numbers, and (3) viscosity ratio. The flow experiments were conducted under a range of confining stresses and flow velocities, using nitrogen gas and silicone oils (of different viscosities) in a specially designed pressure vessel. The sum of gas and oil relative permeabilities were found to be less than one under all conditions, which indicates that the presence of one phase affects the permeability of the other phase, and vice versa. Since the gas phase flow conditions include a significant inertial flow component in addition to viscous flow, the inertial flow coefficients at different saturation states are presented. The factors affecting the relationship between the relative permeabilities are discussed in detail. A new mathematical model for estimating the relative permeability of wellbore cement fracture is presented and experimentally validated.

58 GEOSCIENCES↗
DOE OSTI2025

Monitoring Fracture Hydromechanical Evolution in the Lab and Field Using Unsupervised Metric Learning

Fractures evolve in time through thermal‐hydraulic‐mechanical‐chemical (THMC) processes that alter their long‐range hydraulic transport properties and modify subsurface behavior and activities. The location of subsurface fractures makes it necessary to use remote sensing techniques such as passive or active seismic monitoring for fracture characterization. In this paper, we develop a machine learning approach to monitor the evolution of fracture properties using passive seismic sources in a laboratory setting and using active seismic monitoring from the Sanford Underground Research Facility in Lead, South Dakota, at a depth of 1.25 km in amphibolite rock during stimulation of natural fractures as well as during induced fracturing. The unsupervised metric learning technique applies tandem neural networks (twin (Siamese) or triplet) with contrastive loss and adaptive margins to track slowly varying systems for which class or similarity labels are not available. The approach adopts locality‐sensitive hashing to divide time‐ordered contiguous data into an arbitrary number of pseudo‐classes. Contrastive‐loss training with many hash bins generates an evolving latent‐space trajectory. This approach enables unsupervised metric learning for seismic data stacks under the condition of contiguous state sampling and slowly varying fracture properties. The displacement discontinuity theory provides a mechanistic foundation for the fracture‐dependent trajectories that are related to relaxation of fractures with time‐dependent specific stiffness responding to changes in stress or fluid saturation.

02 PETROLEUM↗
DOE OSTI2026

Extended Rice–Thomson analysis and atomistic simulations revealing grain boundary effects on fracture in refractory high-entropy alloys

Significance This work serves to extend the fundamental ductile vs. brittle fracture theory, specifically the Rice–Thomson criterion, by introducing a grain boundary ahead of an initiating crack which propagates at an oblique angle to impinge the boundary. Atomistic fracture simulations on two refractory complex concentrated alloys, the brittle NbMoTaW and the ductile Nb 45 Ta 25 Ti 15 Hf 15 , demonstrate qualitative correspondence with the extended Rice–Thomson criterion and experimental observations. Abstract Understanding how grain boundaries mediate fracture remains a critical challenge in designing ductile, high-performance refractory alloys. Here, we extend the Rice–Thomson criterion to account for the angle between cracks and the impinging grain boundaries (GBs), capturing the competition between intergranular fracture and dislocation-mediated plasticity. Using machine learning interatomic potentials, we performed molecular statics simulations to probe fracture mechanisms in nanocrystalline NbMoTaW and Nb 45 Ta 25 Ti 15 Hf 15 , each with two different grain sizes, revealing trends consistent with experimental observations and the extended Rice model. Comparison with averaged R-curves for bulk samples demonstrates that GBs enhance ductility in Nb 45 Ta 25 Ti 15 Hf 15 in both grain sizes investigated. In contrast, GBs only locally improve fracture resistance in NbMoTaW when cracks are temporarily pinned at GBs inclined at high angles from the crack, but generally promote brittle intergranular fracture. These contrasting behaviors are attributed to differences in GB cohesion, reflecting clear alloying trends that align with ab-initio calculations and trends observed experimentally. Our results bridge classical fracture theory, atomistic simulations, and experimental observations, providing a comprehensive understanding of the fracture mechanisms in nanocrystalline refractory complex concentrated alloys.

36 MATERIALS SCIENCE↗
DOE OSTI2025

A chain stretch-based gradient-enhanced model for damage and fracture in elastomers

Similar to quasi-brittle materials, it has been recently shown that elastomers can exhibit a macroscopically diffuse damage zone that accompanies the fracture process. In this study, we introduce a stretch-based gradient-enhanced damage (GED) model that allows the fracture to localize and also captures the development of a physically diffuse damage zone. This capability contrasts with the paradigm of the phase field method for fracture, where a sharp crack is numerically approximated in a diffuse manner. Capturing fracture localization and diffuse damage in our approach is achieved by considering nonlocal effects that encompass network topology, heterogeneity, and imperfections. These considerations motivate the use of a statistical damage function dependent upon the nonlocal deformation state. From this model, fracture toughness is realized as an output. While GED models have been classically utilized for damage modeling of structural engineering materials (e.g., concrete), they face challenges when trying to capture the cascade from damage to fracture, often leading to damage zone broadening (de Borst and Verhoosel, 2016). This deficiency contributed to the popularity of the phase-field method over the GED model for elastomers and other quasi-brittle materials. Other groups have proceeded with damage-based GED formulations that prove identical to the phase-field method (Lorentz et al., 2012), but these inherit the aforementioned limitations. To address this issue in a thermodynamically consistent framework, we implement two modeling features (a nonlocal driving force bound and a simple relaxation function) specifically designed to capture the evolution of a physically meaningful damage field and the simultaneous localization of fracture, thereby overcoming a longstanding obstacle in the development of these nonlocal strain- or stretch-based approaches. Here, we discuss several numerical examples to understand the features of the approach at the limit of incompressibility, and compare them to the phase-field method as a benchmark for the macroscopic response and fracture energy predictions.

Elastomers↗
DOE OSTI2024

Revealing complex subsurface dynamics with continuous seismic monitoring: Observations using distributed acoustic sensing and surface orbital vibrators during hydraulic fracturing

Understanding hydraulic fracturing is crucial to improving the stimulation of unconventional reservoirs and increasing fluid production. This study develops a novel seismic monitoring technology using distributed acoustic sensing (DAS) and surface orbital vibrators (SOV) to capture fracture seismic response and mechanical properties at high temporal intervals. We analyze continuous time-lapse vertical seismic profiling (VSP) data acquired every hour during the first nine days of treatment of an unconventional reservoir in the Austin Chalk/Eagle Field Laboratory. The VSP data contain clear seismic signals scattered from the activated fractures. The spatiotemporal changes of the fracture reflectivity revealed by the SOV/DAS data correlate well with the observations of fracture locations inferred from low-frequency DAS data. These results capture the fracture opening and closure processes, as well as highlight potential prestage activations of the fractures due to hydraulic connectivity with preexisting fracture systems. Therefore, analysis of the presented data set provides a unique opportunity to understand fracture initiation and subsequent evolution, not only in the context of unconventional resources but also in enhanced geothermal systems.

Correa, Julia↗
DOE OSTI2025

Influence of build direction on the fracture mechanism of 3D printed octet lattices

Here, we investigate the effects of 3D printing build directions on the fracture properties of octet lattice metamaterials made of polylactic acid (PLA) and how these effects vary with the relative density of the lattices. Single-edge notch bend samples are 3D printed in two orthogonal build directions at various relative densities. Our results show that the work of fracture for octet lattices with build directions parallel to the crack plane is significantly higher than those with build directions perpendicular to the crack plane. We also observed that the ratio of specific work of fracture between the two build directions remains nearly constant across different relative densities. In contrast, the ratio of peak load between the two build directions decreases as relative density increases. Furthermore, the build direction dictates the fracture mechanism. While the perpendicular build direction predominantly results in a brittle (mode I) fracture, the parallel build direction leads to a complex, delamination-dominated (mode II type) fracture. This phenomenon is largely governed by the weak interfaces formed between the printed layers and their interaction with the lattice geometry. These results reveal that the build direction governs the fracture mechanism and work of fracture of these lattice metamaterials and is therefore an important design consideration.

3D printed PLA↗