The Mesh Acoustic innovation is an advanced acoustic suppression component developed for fire extinguisher applications using metal additive manufacturing and Powder Metallurgy technologies. The project aims to create a compact, lightweight, and highly efficient sound attenuation device capable of significantly reducing noise levels while maintaining excellent mechanical strength and durability. By combining innovative lattice engineering with additive manufacturing, the solution achieves acoustic performance levels that are difficult or impossible to obtain using conventional manufacturing methods.

At the heart of the innovation is the use of a Triply Periodic Minimal Surface (TPMS) gyroid lattice structure, an intricate three-dimensional geometry characterized by interconnected channels and a very high internal surface area. This geometry is particularly effective at dissipating sound energy through viscous and thermal losses as air moves through the internal network. Unlike traditional acoustic suppression systems that often rely on multiple components, perforated structures, or additional sound-absorbing materials, the Mesh Acoustic design integrates the acoustic function directly into a single metallic component. This reduces assembly complexity, lowers weight, and improves overall system efficiency.

One of the key advantages of the innovation is its ability to provide exceptional acoustic attenuation within a very limited installation space. The gyroid lattice maximizes internal surface area while maintaining structural integrity through thin-wall features ranging from 0.4 to 0.5 mm. This combination of acoustic efficiency and mechanical robustness makes the component particularly suitable for applications where both space and weight are important design constraints. In addition, the monolithic design eliminates the need for secondary acoustic materials, reducing part count and simplifying manufacturing and maintenance requirements.

The technical feasibility of the innovation has been demonstrated through the successful production of functional prototypes using metal additive manufacturing. The TPMS gyroid structure, which would be virtually impossible to manufacture using conventional machining, casting, or forming technologies, can be produced accurately through powder-based additive manufacturing processes. The selected manufacturing route enables precise control of thin-walled lattice features while ensuring dimensional stability and mechanical performance after sintering. Special attention was given to process optimization, material behavior, and powder removal, all of which are critical challenges for highly complex lattice-based designs. The interconnected geometry of the gyroid structure also facilitates efficient removal of unused powder from internal cavities, making industrial production practical and repeatable.

From an economic perspective, the innovation leverages one of the major strengths of additive manufacturing: the ability to consolidate multiple functions into a single component. Although additive manufacturing may have a higher direct production cost than traditional methods for simple parts, the integration of acoustic functionality, structural support, and lightweight design into one component eliminates tooling, assembly operations, secondary processing, and additional acoustic materials. This results in lower system-level costs, reduced inventory requirements, and faster product development cycles. Furthermore, the controlled porosity of the lattice reduces material consumption and component weight, generating additional cost benefits.

The sustainability benefits are equally significant. The gyroid lattice introduces controlled porosity, reducing raw material usage while maintaining the required acoustic and mechanical properties. Compared with fully dense components, the design achieves a 30–50% reduction in weight, lowering material consumption and contributing to overall resource efficiency. Additive manufacturing further supports sustainability through near-net-shape production, minimizing waste compared with subtractive manufacturing processes. Unused metal powder can also be recovered and reused, improving material utilization and reducing environmental impact.

Performance testing indicates that the lattice-based design can achieve an estimated 20–40% improvement in sound attenuation efficiency compared with conventional acoustic suppression solutions. At the same time, manufacturing complexity is reduced through the elimination of multi-part assemblies, leading to an estimated 25–40% reduction in part count and assembly effort and a 15–30% reduction in production lead time.

Overall, the Mesh Acoustic innovation demonstrates how Powder Metallurgy and metal additive manufacturing can enable entirely new acoustic solutions. By combining advanced gyroid lattice structures, lightweight design, high acoustic performance, and sustainable manufacturing, the innovation provides a compact, durable, and highly efficient suppression system that offers significant advantages over traditional acoustic components.