Size plays a crucial role in designing and realizing 3D phononic crystals and elastic metamaterials with ultrawide band gaps. Existing 3D designs with normalized bandwidth larger than 133.3% are typically fabricated from polymers by additive manufacturing in small sizes (lattice constant ≤ 50 mm). Achieving large bandwidths often requires thin ligaments (flexures), which can fail or deform significantly under self-weight when scaled up, affecting unit cell shape and normalized bandwidth. To mitigate stress and deformation problems at larger scales, a modular design is introduced, enabling separate production of high and low stress-bearing components for assembly. A 3D truss-like structure is formed using steel inertial amplification mechanisms as 600 mm truss elements. Optimization yields a wide stop band but results in thin flexures within these mechanisms. To minimize the stresses and deformations in the inertially amplified 3D truss structure, which weighs more than 100 kg, static weight compensation technique is proposed in which some of the flexures are prestressed to a targeted value before assembly. Consequently, very small static deflection is observed due to self-weight. The optimized 3D truss structure is manufactured and tested. It is revealed that the optimized design provides a complete ultrawide stop band for 3D excitations between 6.2 - 87.8 Hz. Despite the large size and weight, and the stress constraints, an ultrawide band gap (173.6%) is attained.
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