Researchers at the University of Illinois Urbana-Champaign and the Technical University of Denmark have developed a new multilayer synthetic material inspired by natural structures like bone and seashells. Each layer of the material responds to stress in its own way. Together, they absorb impact more effectively than any single material can.

This innovation could benefit designers working in automotive design, wearables, packaging, and even architecture, particularly in projects involving impact-resistant or adaptive materials. Its structure supports circularity goals by reducing the need for complex composites and allowing for more efficient use of resources.

Learning from Nature’s Layers

In nature, materials like nacre (mother-of-pearl) use multiple layers to protect marine creatures from damage. These layers don’t just work alone—they act together to absorb shocks. Inspired by this, the research team created a programmable material in which each synthetic layer behaves differently under stress.

When combined, the layers share the mechanical load. This makes the material highly adaptable, with responses that change based on the force it experiences. Such flexibility could improve product safety and material efficiency in a wide range of design applications.

Moving Beyond Traditional Design

Instead of simply copying nature’s behaviour, the researchers designed a customisable system from the ground up. Their method allows engineers to adjust each layer’s behaviour at the microscale. This makes it possible to fine-tune the way the material bends, buckles, or stiffens under pressure.

Unlike existing materials that rely on single-layer structures or lattices, this new approach significantly expands the possibilities for energy absorption. It enables product designers to develop solutions that are both lighter and stronger.

Unexpected Insights from Fabrication

The researchers aimed to create an infinitely repeating structure. In practice, they had to fabricate finite modules. This led to small mismatches between theory and reality. However, they turned this into a benefit. By programming the buckling order of each unit, they found they could store and later decode mechanical information.

This opens the door to materials that don’t just absorb impact but respond intelligently to their environment. Applications could range from smart bandages to shock-resistant packaging or vehicle interiors.

A Step Towards Smarter Materials

There’s still work to be done before this material can be produced at scale. Yet the study shows what’s possible when materials—and people—work together. For designers, this points to a future where materials adapt, respond, and perform far beyond today’s limitations.

Source: University of Illinois Urbana-Champaign
Photo: Chris 73