Sheet and network based functionally graded lattice structures manufactured by selective laser melting: Design, mechanical properties, and simulation

Zhou, Hailun; Zhao, Miao; Ma, Zhibo; Zhang, Zhengwen; Fu, Guang

doi:10.1016/j.ijmecsci.2020.105480

Cited by 157 publications

(49 citation statements)

References 40 publications

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“…For example, the RD of a sheet structure can be effectively controlled by the level parameters of unit cells, and thus the desired mechanical performance can be achieved. The effects on the mechanical properties of RD have been widely investigated [ 30 , 45 ], thus it is simple to obtain the mapping relationship between the design parameters and the mechanical properties. Three different functional graded structures were explored by simultaneously considering RD and SA/V ratio.…”

Section: Resultsmentioning

confidence: 99%

“…When the intermediate space between them is filled with solid materials, two intertwined and interconnected pores would appear separated by the solid wall. Both structures have been utilized to design FGS using similar methodologies based on the implicit function of TPMS [ 30 ]. The greatest advantage of sheet-based structure over network-based structure is the higher surface area to volume ratio (SA/V ratio), which is a significant parameter that affects a variety of biological properties [ 31 ].…”

Section: Introductionmentioning

confidence: 99%

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Design and Characterization of Sheet-Based Gyroid Porous Structures with Bioinspired Functional Gradients

et al. 2020

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A new type of sheet porous structures with functionally gradients based on triply periodic minimal surfaces (TPMS) is proposed for designing bone scaffolds. The graded structures were generated by constructing branched features with different number of sheets. The design of the structure was formulated mathematically and five types of porous structure with different structural features were used for investigation. The relative density (RD) and surface area to volume (SA/V) ratio of the samples were analyzed using a slice-based approach to confirm their relationships with design parameters. All samples were additively manufactured using selective laser melting (SLM), and their physical morphologies were observed and compared with the designed models. Compression tests were adopted to study the mechanical properties of the proposed structure from the obtained stress–strain curves. The results reveal that the proposed branched-sheet structures could enhance and diversify the physical and mechanical properties, indicating that it is a potential method to tune the biomechanical properties of porous scaffolds for bone tissue engineering (TE).

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Section: Resultsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Design and Characterization of Sheet-Based Gyroid Porous Structures with Bioinspired Functional Gradients

et al. 2020

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“…In the last decades, additive manufacturing (AM) technology has emerged as a frontier in the metal manufacturing process, owing to the great geometrical freedom for manufacturing specific structure (such as foams, honeycombs and lattices) with achievable complexity [ 11 , 12 ]. Laser powder bed fusion (LPBF), as one of the AM processes applicable to manufacturing metal products, can fabricate metallic lattice structures conveniently and effectively [ 13 ]. Nevertheless, lattice structures produced by the AM processes are expected to maximize their mechanical properties, while minimizing their weight in order to satisfy consumer-level requirements.…”

Section: Introductionmentioning

confidence: 99%

Compressive Properties of Al-Si Alloy Lattice Structures with Three Different Unit Cells Fabricated via Laser Powder Bed Fusion

et al. 2020

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In the present study, in order to elucidate geometrical features dominating deformation behaviors and their associated compressive properties of lattice structures, AlSi10Mg lattice structures with three different unit cells were fabricated by laser powder bed fusion. Compressive properties were examined by compression and indentation tests, micro X-ray computed tomography (CT), together with finite element analysis. The truncated octahedron- unit cell (TO) lattice structures exhibited highest stiffness and plateau stress among the studied lattice structures. The body centered cubic-unit cell (BCC) and TO lattice structures experienced the formation of shear bands with stress drops, while the hexagon-unit cell (Hexa) lattice structure behaved in a continuous deformation and flat plateau region. The Hexa lattice structure densified at a smaller strain than the BCC and TO lattice structures, due to high density of the struts in the compressive direction. Static and high-speed indentation tests revealed that the TO and Hexa exhibited slight strain rate dependence of the compressive strength, whereas the BCC lattice structure showed a large strain rate dependence. Among the lattice structures in the present study, the TO lattice exhibited the highest energy absorption capacity comparable to previously reported titanium alloy lattice structures.

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“…It seems that pure PA12 goes to plastic regime earlier that TPC and therefore its load bearing and energy absorbing capacity is less than that of the pure TPC sample. As mentioned previously, deformations usually start from the top of the sample that is close to the indenter, and this observation was reported in most of experimental studies [ 15 , 17 , 18 , 21 , 43 ]. Although we do not have any experimental results on multi-material samples, we wanted to have the collapse from the top layers.…”

Section: Resultsmentioning

confidence: 58%

“…In general, by comparing numerical results with the corresponding experimental results by Platek et al [ 34 ], there is a good agreement between the present FEM results and experimental data under such a large deformation. Regarding the deformed configurations of samples ( Figure 6 and Figure 8 ), deformations usually start from the top of the sample that is close to the indenter, and this observation was reported in most of experimental studies [ 15 , 17 , 18 , 21 , 43 ]. It should be mentioned that the difference between the experimental data of 3D printed structures and numerical simulations could be due to geometrical imperfection in the 3D printed samples and simplifications of the model used in the present study.…”

Section: Resultsmentioning

confidence: 60%

Energy Absorption and Mechanical Performance of Functionally Graded Soft–Hard Lattice Structures

et al. 2021

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Today, the rational combination of materials and design has enabled the development of bio-inspired lattice structures with unprecedented properties to mimic biological features. The present study aims to investigate the mechanical performance and energy absorption capacity of such sophisticated hybrid soft–hard structures with gradient lattices. The structures are designed based on the diversity of materials and graded size of the unit cells. By changing the unit cell size and arrangement, five different graded lattice structures with various relative densities made of soft and hard materials are numerically investigated. The simulations are implemented using ANSYS finite element modeling (FEM) (2020 R1, 2020, ANSYS Inc., Canonsburg, PA, USA) considering elastic-plastic and the hardening behavior of the materials and geometrical non-linearity. The numerical results are validated against experimental data on three-dimensional (3D)-printed lattices revealing the high accuracy of the FEM. Then, by combination of the dissimilar soft and hard polymeric materials in a homogenous hexagonal lattice structure, two dual-material mechanical lattice statures are designed, and their mechanical performance and energy absorption are studied. The results reveal that not only gradual changes in the unit cell size provide more energy absorption and improve mechanical performance, but also the rational combination of soft and hard materials make the lattice structure with the maximum energy absorption and stiffness, in comparison to those structures with a single material, interesting for multi-functional applications.

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Sheet and network based functionally graded lattice structures manufactured by selective laser melting: Design, mechanical properties, and simulation

Cited by 157 publications

References 40 publications

Design and Characterization of Sheet-Based Gyroid Porous Structures with Bioinspired Functional Gradients

Design and Characterization of Sheet-Based Gyroid Porous Structures with Bioinspired Functional Gradients

Compressive Properties of Al-Si Alloy Lattice Structures with Three Different Unit Cells Fabricated via Laser Powder Bed Fusion

Energy Absorption and Mechanical Performance of Functionally Graded Soft–Hard Lattice Structures

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