The effect of geometric design and materials on section properties of additively manufactured lattice elements

Almalki, Abduladheem; Downing, David; Noronha, J.; Dash, Jason; Lozanovski, Bill; Tino, Rance; Alghamdi, Ahmad; Khorasani, Mahyar; Qian, Ma; Brandt, Milan; Leary, Martin

doi:10.1007/s00170-023-11251-1

Cited by 3 publications

References 30 publications

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Additively Manufactured Functionally Graded Lattices: Design, Mechanical Response, Deformation Behavior, Applications, and Insights

Noronha,

Dash,

Leary

et al. 2023

JOM

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Flora and fauna have evolved to distribute their structural mass efficiently in response to their environment. Inspired by this structural efficiency, functionally graded lattices (FGL) are an emerging subset of non-uniform lattices that employ density gradients for a function-driven mechanical response. These gradients are controlled by stepwise or continuous changes in the geometry or topology of the lattice unit cells. FGLs have the capacity for multifunctionality, facilitating high compliance and energy absorption, or moderate strength and stiffness depending upon the specific gradient. These novel lattice structures have been utilized for a range of applications, including biomimetic implants, heat dissipation, and impact absorption. The fabrication of FGLs with complex internal topologies is facilitated through additive manufacturing (AM) using materials such as metals, polymers, and composites. The mechanical properties of these lattices have been examined through compressive testing. The elastic modulus and the yield stress are reported to range from 0.009 GPa to 6.0 GPa, and from 0.38 MPa to 424 MPa for relative densities between 10% and 80%, respectively. Energy absorption is reported to supersede conventional uniform lattices by up to 30%. By accumulating and assessing the mechanical, geometric, and topological data from the FGL literature, this review will systematically classify and explore the viability of these novel structures for real-world applications.

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Additively Manufactured Functionally Graded Lattices: Design, Mechanical Response, Deformation Behavior, Applications, and Insights

Noronha,

Dash,

Leary

et al. 2023

JOM

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A Manufacturability Evaluation of Complex Architectures by Laser Powder Bed Fusion Additive Manufacturing

McGregor,

Patel,

Zhang

et al. 2024

Journal of Manufacturing Science and Engineering

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Additive manufacturing (AM) enables new possibilities for the design and manufacturing of complex metal architectures. Incorporating lattice structures into complex part geometries can enhance strength-to-weight and surface area-to-volume ratios for valuable components, particularly in industries such as medical devices and aerospace. However, lattice structures and their interconnections may result in unsupported down-skin surfaces, potentially limiting their manufacturability by metal AM technologies, such as laser powder bed fusion (LPBF). This study aimed at examining the correlation between down-skin surface area and the manufacturability of lattice structures fabricated using LPBF. Image processing algorithms were used to analyze down-skin surface areas of seven unique lattice designs and to devise quantitative metrics (such as down-skin surface area, discrete surface count, surface inter-connectivity, down-skin ratio, over-print/under-print volumes, etc.) to evaluate LPBF manufacturability. The seven lattice designs were subsequently manufactured using maraging steel via LPBF, and then examined using imaging using X-ray micro-computed tomography (XCT). The geometric accuracy of the lattice designs was compared with XCT scans of the manufactured lattices by employing a voxel-based image comparison technique. The results indicated a strong relationship between down-skin surface area, surface interconnectivity, and the manufacturability of a given lattice design. The digital manufacturability evaluation workflow was also applied to a medical device design, further affirming its potential industrial utility for complex geometries.

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The Downside of Downskin: An Overhang Ratio to Digitally Evaluate Printability of Complex Architectures by Laser Powder Bed Fusion Additive Manufacturing

McGregor

Patel

Zhang

et al. 2023

Preprint

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The effect of geometric design and materials on section properties of additively manufactured lattice elements

Cited by 3 publications

References 30 publications

Additively Manufactured Functionally Graded Lattices: Design, Mechanical Response, Deformation Behavior, Applications, and Insights

Additively Manufactured Functionally Graded Lattices: Design, Mechanical Response, Deformation Behavior, Applications, and Insights

A Manufacturability Evaluation of Complex Architectures by Laser Powder Bed Fusion Additive Manufacturing

The Downside of Downskin: An Overhang Ratio to Digitally Evaluate Printability of Complex Architectures by Laser Powder Bed Fusion Additive Manufacturing

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