Abstract
In this study, authors explore the application of modelling and additive layer manufacturing (ALM) for creating and testing materials with interlocking structures aimed to reduce the stress concentration along the edges of a typical lap joint. The effectiveness of this approach is discussed by means of modelling and experimental validation of joints with interlocking structures obtained by ALM. Considering the achieved results, ALM of interlocking structures constitutes an interesting alternative or complement to traditional joining processes, as it may help to minimize stress mismatches in the joining region. It may also prevent the use of adhesive or joining post processes, because the joint is created together with the joined components.