Magnetically Actuated Honeycomb Metastructure: A Design Framework for Tuneable and Reconfigurable Metastructures

  • Gupta, Tanuj (Indian Institute of Technology Kanpur)
  • Pathak, Suryansh (Indian Institute of Technology Kanpur)
  • Dwivedi, Ankur (Indian Institute of Technology Kanpur)
  • Bhattacharya, Bishakh (Indian Institute of Technology Kanpur)

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The demand for next-generation reconfigurable structures has shifted focus toward materials capable of rapid, non-contact actuation and reversible shape morphing. While conventional soft actuators often suffer from slow response times and high energy dependency, magneto-mechanical metamaterials offer a promising solution by combining structural ingenuity with non-contact magnetic control. The study presents the design optimization and validation of a composite honeycomb based metastructure integrated with discrete magnetic inclusions for programmable deformation and tuneable stiffness. The metastructure was fabricated using Thermoplastic Polyurethane (TPU 95A) to provide a flexible matrix, reinforced with Polylactic Acid (PLA) inserts to localize mechanical stress at the unit cell edges. Permanent 5 mm cubic Neodymium (NdFeB, N42) magnets were embedded within the honeycomb pockets in distinct spatial configurations. The interaction between the internal magnetic remanence and an externally applied magnetic field enables the system to achieve large-scale, rapid deformation without physical tethering. A Multiphysics numerical model was developed in COMSOL 6.3, coupling Solid Mechanics and Magnetic Fields to predict the structural response. Experimental validation was conducted using a customized Helmholtz coil setup, where deformation was measured via a single-point Laser Displacement Sensor. Results demonstrate that the metastructure’s stiffness and deformation patterns are highly sensitive to the orientation of the internal magnets and external magnetic field intensity. The dual-mode control-combining passive pre-programming and active field modulation make this metamaterial exceptionally suited for soft robotic gripper, adaptive biomedical implants, and active vibration damping systems.