The layer-by-layer additive manufacturing approach results in the 3D printed composite lattice structure fails to exploit fiber reinforcement, thereby resulting in inferior mechanical qualities. To address this challenge, this study proposes a novel approach leveraging composite fused filament fabrication (FFF) printing to design modular assembled composite lattice structures. Initially, three high-performance lattice structures were transformed into discrete 2D components and assembled into 3D lattice structures. Subsequently, the mechanical properties of these structures were comprehensively assessed using theoretical, experimental, and finite element analysis methods. Finally, the comparison between the assembled structures and integrated printed lattice structures in terms of surface quality, mechanical properties, and manufacturability revealed significant advantages. The theoretical and finite element analyses accurately predicted the mechanical properties of the lattice structures. The lattice structures that were assembled in a modular way displayed an impressive 74% improvement in surface finish. Additionally, they showed peak strength increases of 140%, 27%, and 26%, respectively, for the mentioned types of topology. The energy absorption also increased significantly by 510.83%, 44.18%, and 30.24%. Furthermore, these assembled structures required less printing support materials, enhancing their manufacturability and cost-effectiveness. This new method of designing modular space structures goes beyond the limitations imposed by equipment by using high-performance topology. It allows for the construction of large-scale, lightweight space structures that offer excellent performance. This study explores innovative opportunities in the field of space manufacturing, offering potential implications for the development of lunar habitats, space telescopes, and space power stations.
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