PAMs – 3D Printed Chain Mail for the 21st Century

A recent breakthrough in Architected materials science could revolutionize how the world thinks of matter. Through the use of specially designed interlaced architecture and new materials, engineers created PAMs (polycatenated architected materials), an entirely new class of matter with unique behavior properties, and more. Here's everything you need to know.

Architected Materials

Architectural materials have been a point of scientific study for 30+ years. They are unique in many ways including their design with wireframe elements interwoven into three-dimensional structures. Additionally, their structure and materials work together to create their mechanical properties.

PAMs Study

A recent study published in Science called  “3D polycatenated architected materials.”¹ delves into a new type of architected material and structure. This new approach was designed to replicate nature's crystalline architecture. The main difference is that the engineers replaced the crystals with fixed particles with cages or rings.

Source – Wenjie Zhou

This structure looks very similar to chainmail armor, providing flexibility and protection from impact. PAMs feature rings interlocked in three-dimensional networks like chain armor but aren't limited to any particular style or shape. Using computer simulations, engineers can create an array of PAMs that operate differently based on their layout and design elements.

Does Not Naturally Occur

One of the most interesting aspects of PAMs is that their structure is completely man-made. It doesn't exist in nature. This unique design makes PAMs a new type of matter that can behave like a solid or liquid, depending on the scenario.

PAMs can achieve this unique characteristic due to their use of interwoven components. The individual particles are linked in crystalline structures but retain the ability to move relative to one another.

Think of a box of sand being moved around. The sand particle can move freely to accommodate any pressures. PAMs do the same thing only using a lattice interwoven structure. They can flow, change positions, and adjust when required.

Electric PAMs

The study also delved into how electrostatic charges could alter the characteristics of PAMs. This adjustability would allow engineers to fine-tune their PAMs or use them across a wide selection of industries, including robotics.

PAMs Test

To test their theory, the engineers began by 3D printing PAMs. They decided to make multiple versions to test their durability and capabilities. Specifically, the materials used to create the PAMs ranged from acrylic polymers, and nylon, all the way to traditional metals. The team printed several 2-inch cubes or spheres with a 5-centimeter diameter for the testing phase.

PAMs Stress Tests

Multiple stress tests were used to determine the durability and overall strength of the new PAMs.

Under Compression

The researchers placed the PAM under compression to see its reaction. They then gradually heated up the PAM, testing to see its effect. Notably, it proved extremely durable in compression testing.

Tearing Force

The next test was to see how hard it would be to tear the material. The device didn’t hold up well to the sheer lateral force and could be torn easily from applied pressure. This discovery wasn't a huge surprise as the material was never intended to be used to prevent tearing forces.

Twisting force

The final stress test measured twisting force. Here, the engineers utilized rheology tests to determine speed and movement accurately. This part of the test gradually increased intensity until the twisting force broke the printed piece.

PAMs Test Results

The PAMs study yielded some interesting results. For one it proves that PAMs exhibit classic fluid and solid behavior. When force is applied to the material, it stiffens up like a rock, but in other scenarios, it can act like a liquid.

The test results prove that PAMs are controlled by their catenation topologies. As such, changing the shape of the design alters the unit's resistance and ability. Tested PAMs became very hard when compressed. Additionally, it would alter shape and structure under small electrical loads.

Small External Loads

PAMs behave like non-Newtonian fluids when a small force is applied to them. The test subjects possessed both shear-thinning and shear-thickening responses to small external loads.

Large Strains

Larger strains put more stress on the material, resulting in nonlinear stress-strain relations. This stress-strain relationship can lead to future issues if not inspected and corrected when first noticed.

Benefits of PAMS

PAMS will introduce many benefits to the market. For one, they provide a new and highly efficient way to dissipate energy effectively. These units can take a lot of hits because they can change their shape to increase their structural integrity.

Customization

PAMS can be customized to suit nearly any specific case. You can create them out of rigid hard or stretchable soft materials. They can also be 3D printed and the shape of each particle can be altered to achieve a desired effect or structure. Also, even the lattice that connects the particles is interchangeable.

Use Case for PAMs

There are several use cases for PAMs. These materials could see widespread adoption in the near future from multiple industries seeking to reduce costs, improve safety, and enhance their business model. Here are just a few use cases for this tech.

Logistics

You can expect to see PAMs find a home in protecting items during transport. Packaging material made from PAMs would be super lightweight and could help to prevent damage from dropping or losing it. Additionally, the material could be reusable and recyclable, making it a better solution than cardboard.

Safety Equipment

PAMs will one day make your helmet smaller and your safety gear more durable. Items designed to take impact like knee pads will see immediate protection. Additionally, other safety gear like gloves will get more durable.

HealthCare

Biomedical devices are another use case scenario for adjustable micro PAMs. This material could one day help to save leaves. Imagine a doctor stimulating PAMs to hold an artery open. Additionally, wearables will become more durable and comfortable.

Energy-Absorbing Systems

Imagine using PAMs to prevent serious injuries. This lightweight material could one day be used to create stronger car components without needing a ridiculous amount of funding.

Morphing Architectures

Picture robots searching through rubble for any survivors. Suddenly, it receives a sign of life from below the shattered ruins. The device then alters its shape to fit into the smallest crack to further investigate the sounds. Morphing robots are becoming more popular due to their unique ability which could be a major upgrade thanks to this study.

A Leader in Additive Manufacturing

There are so many industries this research could help to benefit In the near future. From extra light protective gear to making your car safer and lighter, PAMs have a place in the market. Here's one company that’s positioned to utilize PAMs and improve its offerings.

Stratasys

Stratasys (SSYS +5.47%)  is an Israel-based additive manufacturing research and development firm. It entered the market in 1989 and quickly rose up the ranks to become a dominant force in the sector. Interestingly, the company originated after the founder attempted to create a 3D frog using layers and a mixture of polymer and glue. Fast forward a few years and Stratasys's 3D Modeler became a hit.

Today, Stratus specializes in the research and development of new-age polymers. These materials have a wide range of applications across the aerospace, industrial, automotive, recreational, electronic, medical, and consumer markets.

Since its launch, Stratasys has managed to secure a massive clientele list that includes governments, and major conglomerates. The company hasn't stopped expanding. Recently, it announced a $1.8B merger with Desktop Metal Hue designed to enhance its offering further.

SSYS is a reliable stock that has remained a stronghold for years. The company's positioning and innovative record have helped it to remain a top pick for traders across the board. As the firm introduces some of its latest AI-inspired products, there could be a significant upswing.

PAMs – Chainmail Printed and ready to GO

The PAM study reveals a new type of matter that shares characteristics with solids and liquids. It can provide protection or passage if needed. Additionally, it has unlimited customization, making it the ideal choice for a variety of tasks in the future. For now, hats off to this innovative team of engineers for achieving this milestone.

Learn about other cool Additive Manufacturing stories here

Study Reference:

^{1. Zhou, W., et al. (2025). 3D polycatenated architected materials. Science, 387, 269–277. https://doi.org/10.1126/science.adr9713}