I have a basic geometric unit '1.1.1mm cube' with the minimum vertex count that I could reach. I would like to duplicate it using an array modifier to make a X7,Y40,Z25mm bigger cube, 0.8mm offset. Although I've checked the merge option, and used mesh clean to merge vertices, the vertex count and file size get inflated, and the computer freezes. Anyone have better design ideas or solutions? You can download the file from this link:
https://drive.google.com/file/d/11KlTY1PrDhpRBqAkAs8UabRv6ehmPYul/view?usp=sharing 
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Your computer might be short of power for 5 million polygons, as I can make the array on mine OK.
You do have 211 unneeded vertices that you can get rid of by selecting one of them then Select -> Select Similar -> Amount of Connecting Edges, then press DEL and Dissolve Vertices
Also, your mesh doesn't look to be symmetrical so merging either creates holes, or, if the merge distance is set to 0.0, you get overlapping geometry. Here is a version of your cube that I have Mesh -> Bisected to produce the minimum unit. This can then be mirrored to generate your cube again. 
PS here's an outline showing one way to make a grid of tubes with geometry nodes 
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$\begingroup$ Fantastic, Thank you so much paddyg for your help. Now I can run it much more smoothly on my computer. $\endgroup$ Mar 13 at 0:49
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$\begingroup$ Also, I don't know what your objective is overall here but you could probably make an array of intersecting pipes using geometry nodes, with bevelled curves. $\endgroup$– paddygMar 14 at 12:13
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$\begingroup$ Thank you for following up, my objectives is to build different shapes using this unit cube. However sometimes the outer struts have to be tapered from the first unit upwards ⬆️… still thinking how to solve it. Can you refer me to a video explaining your 2nd method. $\endgroup$ Mar 15 at 23:11
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$\begingroup$ Could you please explain more about using "intersecting pipes using geometry nodes, with beveled curves" Thank you $\endgroup$ Mar 22 at 2:19
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$\begingroup$ my target is a bigger cube so that I can do a Boolean modifier on it to make tunnels with different shapes. Now it gets freeze when I try to drive.google.com/file/d/1X84FT0VCDkWTY4zepHBbqfAb37T9XWn1/… $\endgroup$ Mar 22 at 2:22