Search

Additive Manufacturing (AM) technology offers remarkable flexibility in fabricating products with intricate geometries, presenting unprecedented advantages in material efficiency and speed. The process planning of AM plays a pivotal role in ensuring overall quality and time-efficiency of printed products. This drives engineers and researchers to explore various approaches to achieve optimal AM process solutions. However, numerous challenges persist, particularly in logical relationship reasoning and information representation for complex manufacturing tasks and design requirements. In this study, a novel AM process reasoning method based on relation mining is proposed, leveraging knowledge graph representation and graph neural networks (GNN). An AM knowledge graph is constructed comprising essential process information, followed by implementing RED-GNN to accomplish graph reasoning tasks for parameter recommendation. We then focus on the process planning scenario of lattice structures, a common geometry used for designing products with weight-relief requirements and high sensitivity to process parameters. A series of lattice structure parts are designed and tested using our proposed method, demonstrating strong performance and unveiling new potentials and opportunities in advancing knowledge-based engineering and intelligent manufacturing. [ABSTRACT FROM AUTHOR]

In the current study, a new type of novel lattice structures with the concept of bio-mimicking three different nature-inspired designs from the honeycomb patterns, the overlapping phenomenon of the scales present on fish dermal layers, and scutes pattern observed from the top skin layers present on crocodile species are developed. These lattice structures are designed within a cubic volume of 30 mm. The design of lattice unit cells is made with two different geometrical sizes of 4 and 6 mm with different overlapping areas of 20, 30, 40, and 50% calculated from each cell area. All the unit cells' walls are maintained at 0.4 and 0.6 mm only. The specimens are modeled and manufactured through the VAT photopolymerization process, one of the significant additive manufacturing principles for great dimensional accuracy with negligible defects in 3D printing (3DP). The research approach used to develop lightweight bio-inspired structures has been laid out, starting with observing design that served as inspiration. The cured 3D-printed specimens are examined under quasi-static compressive loading carried out on all specimens as per ASTM 1621 standards to measure the crashworthiness response of designed specimens. The energy ingestion capacity of all the specimens is assessed. A good correlation is observed between the experimental and numerical results for better validation. The best design parameters among all 16 specimens are identified for applying energy absorption applications in the automobile and aviation fields in real-time. [ABSTRACT FROM AUTHOR]

Multi-material lattice structures demonstrate superior mechanical advantages and lightweight potential, enabling it preferable in many engineering fields, especially with the rise of additive manufacturing. However, employing multi-scale topology optimization inherently involves computational complexities of designing the macromaterial distribution and microlattice geometric size simultaneously. In this paper, a modified relative density mapping (MRDM) method is proposed, which generates a multi-material lattice structure by projecting the continuum multi-material topology optimization results. The proposed method extends the standard relative density mapping (RDM) method to multi-material problem and improves the performance. To achieve such purpose, a new mapping relation considering multi-material density and stress information is introduced to generate mapping weight of materials, which is the most novel contribution. Second, to avoid intersection of different materials, two types of material mapping strategies, namely continuous mapping strategy, and discrete mapping strategy, are introduced to generate multi-material lattice structure using the mapping weight of materials. Several numerical examples are exhibited, which demonstrate that the proposed method is capable of generating a multi-material lattice structure with clear material interface and good performance. [ABSTRACT FROM AUTHOR]

This paper compares the results of a theoretical approach, finite element analysis (FEA) and mechanical tests of monolithic TA6V Dode-Thin lattice core sandwich structures manufactured by powder bed laser beam melting process. An analytical approach to evaluate the mechanical properties of one Dode-Thin strut is briefly presented. The strut is then replaced by an equivalent beam whose cross-section is a solid circle. Various finite element (FE) models are used to calculate the effective mechanical properties of a defect-free structure and compared to the analytical results of beam theory. Besides the calculations, different experimental tests and measurements are carried out to measure the stiffness of the sandwich beams. These experiments show that both theoretical and numerical predictions significantly overestimate the stiffnesses. The discrepancies between the models and the as-built components are mainly due to geometrical imperfections and internal defects (porosity) caused by the AM process. Optical observations and X-ray computed tomography (CT) are then performed to determine the actual cross-sectional properties of the struts. Finally, this study provides the engineer with a simple method to replace a Dode-Thin strut with an equivalent beam of solid circular cross-section, and to define the equivalent 3D-orthotropic material with homogenized mechanical properties. Another contribution of this work is the insight into the as-built physical parameters to improve the correlation between models and experimental data. [ABSTRACT FROM AUTHOR]

Multicell design and lattice structure as filling material are two effective methods for enhancing the energy absorption performance of thin‐walled tubes. This study combines these two approaches to present a multicell tube with a novel lattice structure and investigates the energy absorption performances of these hybrid multicell tubes under axial (0°) and oblique (10°, 20°, and 30°) impact loading conditions. As filling structure, β‐Ti3Au lattice geometry with varying lattice strut diameters and the number of lattice unit cells are used, while the single and multicell thin‐walled tubes with different tube thicknesses are employed as main absorbing element. In this context, the effects of numbers of lattice unit cells, lattice strut diameter, cell numbers of the tube, and tube thickness on energy absorption performance of hybrid tubes are examined using validated nonlinear finite element models. This investigation unveils that the synergistic interplay between the multicell tubes and lattice structure during deformation significantly elevates the energy absorption performance of the hybrid structure. Notably, the findings demonstrate that multicell hybrid tubes exhibit a remarkable capacity to absorb up to 30.36% more impact energy compared to the aggregate absorption of individual components in hybrid tubes. [ABSTRACT FROM AUTHOR]

The objective of this research is to explore the scale effect on the mechanical properties of sheet‐based triply periodic minimal surface (TPMS) uniform lattice structures fabricated with PLA (polylactic acid) under quasi‐static loading conditions. The scale dependency was evaluated by two additional breakdown categories, namely, wall thickness effect and unit cell size effect. Deformation mechanisms and failure modes as well as mechanical properties including stiffness, yield strength, first peak stress, and energy absorption based on the categories of wall thickness, unit cell size, and scale were evaluated experimentally. The assessment of the scale effect involved considering the combined influence of wall thickness and unit cell size. In addition, numerical analysis was also performed to investigate the stress distributions and compare with the experimental results for certain geometries. Ultimately, the relation between the normalized mechanical properties and relative density is evaluated and categorized, which can be used as an indication for future design practices. Highlights: Scale, wall thickness, and unit cell size effect of lattice structures were studied.Relative density played a significant role in determining mechanical properties.Unit cell size to wall thickness ratio is critical for different failure mechanisms.Normalized mechanical properties were evaluated for the future design. [ABSTRACT FROM AUTHOR]

3D Kagome lattice sandwich structure is recognized as the most excellent lattice configuration. However, the preparation method of 3D Kagome is complicated and the raw materials for its preparation are limited to materials with high plasticity. In this study, we developed a wood-based 3D Kagome lattice structure that combines discrete rods into a continuous core using reinforcement. Orthogonal tests, theoretical analysis, and finite element simulations were performed to investigate the correlation between the dimensional parameters, the mechanical properties, and the energy absorption capacity. The damage modes were found to be mainly bending fracture, core shear, and panel rupture, with the use of reinforcement affecting the damage modes. Compressive properties of the 3D Kagome lattice structure are increased by increasing core diameter and inclination degree, decreasing core in-cut diameter, and using high-strength reinforcements. Finite element simulations further confirm that the use of high-strength reinforcements changes the stress distribution of the lattice structure. The 3D Kagome lattice structure with an inclination degree of 65°, a core diameter of 10 mm, a reinforcement wall thickness of 2 mm, and a core in-cut diameter of 2 mm has the optimal compression performance and energy absorption capacity. [ABSTRACT FROM AUTHOR]

Additive manufacturing provides new possibilities in product design compared to traditional manufacturing processes. Particularly additive material extrusion offers the freedom to combine multiple materials in a single component without additional steps. However, combining multiple materials often leads to reduced adhesion, which can hinder the creation of high-strength designs. This issue can be largely mitigated using the geometric freedom of additive manufacturing to produce interlocking structures. This publication investigates the use of lattice structures as interlocking bonds in multi-material applications. The aim is to aid the design of suitable lattice structures by collecting geometric freedoms of lattices, application requirements, and manufacturing constraints, for this information to be used in suitable designs in the future. Initially, the general design freedoms of lattice structures are compiled and explained. Subsequently, these design freedoms are narrowed down based on the specific requirements for interlocking bonds and the limitations imposed by geometry and material combinations during manufacturing. The publication concludes with design recommendations that can be used as the basis for interlock bonds. Suitable lattice designs should aim for high interconnectivity, interconnected porosity, and a high number of similar strut structures, all the while maintaining low dimensions in the interface direction. [ABSTRACT FROM AUTHOR]

Lattice structures show advantages in mechanical properties and energy absorption efficiency owing to their lightweight, high strength and adjustable geometry. This article reviews lattice structure classification, design and applications, especially those based on additive manufacturing (AM) technology. This article first introduces the basic concepts and classification of lattice structures, including the classification based on topological shapes, such as strut, surface, shell, hollow-strut, and so on, and the classification based on the deformation mechanism. Then, the design methods of lattice structure are analyzed in detail, including the design based on basic unit, mathematical algorithm and gradient structure. Next, the effects of different lattice elements, relative density, material system, load direction and fabrication methods on the mechanical performance of AM-produced lattice structures are discussed. Finally, the advantages of lattice structures in energy absorption performance are summarized, aiming at providing theoretical guidance for further optimizing and expanding the engineering application potential of lattices. [ABSTRACT FROM AUTHOR]

The increasing application of additively manufactured (AM) materials in engineering and biomedical fields highlights the necessity of understanding their mechanical behavior, particularly with complex lattice structures. Polylactic acid (PLA), a popular biopolymer in additive manufacturing, exhibits mechanical characteristics highly dependent on its structural design. This research investigates the quasi‐static puncture failure analysis and mechanical characteristics of additively manufactured (AM) polylactic acid (PLA) materials with various lattice structures. The mechanical behavior, including tensile strength, flexural properties, interlaminar shear strength (ILSS), Izod impact resistance, and quasi‐static punch shear strength (QS‐PSS), was investigated following the respective ASTM protocols. Results indicate a 6% increase in tensile strength, to ca. 28 MPa, for the triangular PLA lattice structure compared with plain lattice structures. In the flexural test, the hexagonal structure showed a 13% increase in bending strength, to ca. 45 MPa, compared with the plain structure. Additionally, the hexagonal PLA lattice structure exhibited a 24% increase in shear strength, to approximately 8 MPa, over the plain lattice structure in the interlaminar shear strength analysis. In the Izod impact analysis, the plain lattice structure demonstrated a 17% increase in impact strength, to ca. 278 J/m, compared with the circular structure. A stainless‐steel hemispherical indenter was employed to investigate the quasi‐static punch shear behavior (QS‐PSS) of different lattice structures. The triangular structure displayed increased total energy absorption capacity and specific energy absorption of ca. 19 J and 0.529 J/g, respectively, compared with other lattice structures. These results are important for the creation of additively manufactured PLA lattice structures, improving the puncture resistance of advanced composites. Highlights: Polylactic acid (PLA) lattice structures were fabricated.Plain, circular, triangular, and hexagonal lattice structures were investigated.Lattice structures were used as reinforcements.The triangular structure demonstrated improved strength.The triangular structure reduced crack formation and propagation. [ABSTRACT FROM AUTHOR]

The application of two-dimensional lattice structures is increasingly prevalent due to their significant potential in various multifunctional applications such as energy absorption, heat dissipation, and sound insulation. Similar to phononic crystals, lattice structures exhibit periodicity, and being composed of lightweight rods, they are sensitive to vibrations. Incorporating the concept of acoustic metamaterials into lattice structures can facilitate the design of lattices with vibration isolation properties. However, the low-frequency bandgaps generated by local resonances in lattice structures tend to be narrow. To widen the frequency range of these low-frequency bandgaps, several studies have emerged. This study focuses on rapidly optimizing the phononic bandgaps of two-dimensional lattice structures, aiming to efficiently and accurately determine the optimal geometry of each truss unit, thereby exhibiting outstanding vibration (elastic wave) isolation within a specific frequency range (bandgap). The proposed approach employs an Extended Multiscale Finite Element Method (EMsFEM) to achieve equivalence in the mechanical performance of truss structures, enabling the rapid computation of bandgap optimization for lattice structures with large-scale truss units. The results illustrate the effectiveness and feasibility of this method, which can attain broadband low-frequency bandgaps without compromising computational efficiency. [ABSTRACT FROM AUTHOR]

The modern additive manufacturing process enables the fabrication of innovative structural designs of lattice structures with enhanced mechanical properties. Characterizing the designability of lattice geometries and the corresponding mechanical performance, particularly the compressive strength is vital to commercializing lattice structures for lightweight components. In this paper, a Novel hybrid type of lattice structure was developed inspired by the overlapping pattern of scales on dermal layers of the species like fish and circular patterns observed from the bamboo tree structure. This research designed the lattice cell with 20%,30%,40%, and 50% overlapping areas based on the proposed circular area. The unit cell wall thickness varies between 0.4 mm and 0.6 mm. The designed structures with a constant volume of 40x40x40 mm, varied circular diameters, overlapping areas, and unit wall thickness are modeled in Fusion 360 software. 3D-printed lattice structures were fabricated using the vat polymerization type three-dimensional printing machine using the principle of stereolithography (SLA) technique. Then, the 3D-printed specimens are tested for quasi-static compressive response in a universal testing machine (UTM) by following ASTM standards. The test results are evaluated and compared with the simulation results. Finally, the best lattice structure is selected for energy absorption application in the aerospace and defense sectors. [ABSTRACT FROM AUTHOR]

Cellular lattice structures encompass a class of metamaterials characterized by the arrangement of interconnected struts and/or plates, offering an adaptable microstructure that enables a broad range of property control. These structures have garnered significant attention for their distinctive properties and have found widespread application across industries such as aerospace, medical, pharmaceutical, automotive, defense and safety. This study seeks to explore the impact of geometric parameters on the natural frequency and damping coefficient of cellular lattice structures. Samples featuring BCC and OCTET architectures with varying porosities were initially produced using fused deposition modeling (FDM). Subsequently, both experimental and numerical analyses were conducted to assess the first natural frequency and damping coefficient of these materials. Comparison of the numerically obtained results with experimental data revealed a strong agreement. The findings indicate that, for both BCC and OCTET lattices, an increase in porosity is associated with a decrease in both natural frequency and damping coefficient.

A novel 3D centrosymmetric lattice that exhibits a large twist angle during compression is proposed by tailoring the twist buckling mode of a body-centered cubic lattice and a simple cubic truss to the first. The imperfections of offset and multimaterial systems are introduced to control the twist direction. Effects of geometrical parameters and material properties on twist behavior are studied. Results suggest that the buckling-driven lattice configuration can twist at an angle of 100° and an average angle per unit axial strain of 6.7°/%. The novel configurations can be used as force switches, safety devices, and temperature-controlled transmission devices. [ABSTRACT FROM AUTHOR]

This paper presents novel configurations for additively manufactured lattice structures, including helical and elliptic designs, in addition to the pyramid base model. Functionally graded versions of the pyramid and elliptic lattice structures are developed by considering desirable relative densities in each layer. The lattice structures were manufactured using Ti-6Al-4V powder in a three-dimensional selective laser melting printer. The averaged porosities are 0.86, 0.91, 0.916, 0.93 and 0.74 for pyramid, functionally graded pyramid, elliptic, functionally graded elliptic and helical, respectively. The mechanical behavior of the lattice structures was characterized through compression tests using a universal testing machine and computationally analyzed using finite element code. The results indicate that the elliptic and functionally graded elliptic lattices have elastic moduli of 0.76 and 0.67 GPa, while the yield strengths are 41.32 and 32.24 MPa, respectively, in comparison to cancellous bone. Moreover, pyramid, functionally graded pyramid, and helical lattices show relatively lower elastic moduli of 0.57, 0.65 and 0.41 GPa and higher yield strengths of 54.1, 52.15 and 61.02 MPa, respectively. This could be an indication that they are fit for cortical bones. All samples have low elastic moduli coupled with high yield strengths. This could reduce or eliminate stress shielding, making them suitable for some load-bearing bio-inspired applications. A comparative study utilizing experimental and numerical models was conducted to evaluate the performance of the proposed designs. [ABSTRACT FROM AUTHOR]

In the present work, the influence of defects on the compressive response of octet‐truss AlSi10Mg lattice structure specimens produced with a selective laser melting process is investigated. The defect population in one cell, in two cells, and cubic specimens composed of 27 cells has been assessed with micro‐computed tomography (micro‐CT) analyses. The statistical distributions of the characteristic defect sizes, i.e., the equivalent diameter, the volume, and the surface, assessed in the lattice structure specimens and in volumes randomly extracted from a rectangular bar have been compared. Finally, the compressive behavior of lattice structure specimens has been simulated with a simplified damage‐tolerant finite element model accounting for the influence of defects and compared with experimental results. The analyses have proven that the defect population in volumes extracted from a rectangular bar can provide reliable simulated results, even if micro‐CT inspections of a unit cell or specimens made of several cells are suggested. Highlights: Manufacturing defects strongly influence the structural integrity of lattice structures.Defect volume, surface, and equivalent diameter are reliable characteristic defect sizes.The defect population should be assessed on multiple cells for damage‐tolerant design.Finite element analyses should model the influence of defect size. [ABSTRACT FROM AUTHOR]

Phononic crystals based on lattice structures provide important wave dispersion characteristics as band structures, showing excellent compatibility with additive manufacturing. Although the lattice structures have shown the potential for vibration suppression, a design guideline to control the frequency range of the bandgap has not been well established. This paper studies the dispersion characteristics of plane wave propagation in lattice-based mechanical metamaterials to realize effective vibration suppression for potential aerospace applications. Triangular and hexagonal periodic lattice structures are mainly studied in this paper. The influence of different geometric parameters on the bandgap characteristics is investigated. A finite element approach with Floquet–Bloch's principles is implemented to effectively evaluate the dispersion characteristics of waves in lattice structures, which is validated numerically and experimentally with a 3D-printed lattice plate. Based on numerical studies with the developed analysis framework, the influences of the geometric parameters of lattice plate structures on dispersion characteristics can mainly be categorized into three patterns: change in specific branches related to in-plane or out-of-plane vibrations, upward/downward shift in frequency range, and drastic change in dispersion characteristics. The results obtained from the study provide insight into the design of band structures to realize vibration suppression at specific frequencies for engineering applications. [ABSTRACT FROM AUTHOR]

The properties of each lattice structure are a function of four basic lattice factors, namely the morphology of the unit cell, its tessellation, relative density, and the material properties. The recent advancements in additive manufacturing (AM) have facilitated the easy manipulation of these factors to obtain desired functionalities. This review attempts to expound on several such strategies to manipulate these lattice factors. Several design-based grading strategies, such as functional grading, with respect to size and density manipulation, multi-morphology, and spatial arrangement strategies, have been discussed and their link to the natural occurrences are highlighted. Furthermore, special emphasis is given to the recently designed tessellation strategies to deliver multi-functional lattice responses. Each tessellation on its own acts as a novel material, thereby tuning the required properties. The subsequent section explores various material processing techniques with respect to multi-material AM to achieve multi-functional properties. The sequential combination of multiple materials generates novel properties that a single material cannot achieve. The last section explores the scope for combining the design and process strategies to obtain unique lattice structures capable of catering to advanced requirements. In addition, the future role of artificial intelligence and machine learning in developing function-specific lattice properties is highlighted. [ABSTRACT FROM AUTHOR]

Heat exchangers make it possible to utilize energy efficiently, reducing the cost of energy production or consumption. For example, they can be used to improve the efficiency of gas turbines. Improving the efficiency of a heat exchanger directly affects the efficiency of the device for which it is used. One of the most effective ways to intensify heat exchange in a heat exchanger without a significant increase in mass-dimensional characteristics and changes in the input parameters of the flows is the introduction of turbulators into the heat exchangers. This article investigates the increase in efficiency of heat exchanger apparatuses by introducing turbulent lattice structures manufactured with the use of additive technologies into their design. The study is carried out by numerical modeling of the heat transfer process for two sections of the heat exchanger: with and without the lattice structure inside. It was found that lattice structures intensify the heat exchange by creating vortex flow structures, as well as by increasing the heat exchange area. Thus, the ratio of convection in thermal conductivity increases to 3.03 times. Also in the article, a comparative analysis of the results obtained with the results of heat transfer intensification using classical flow turbulators is carried out. According to the results of the analysis, it was determined that the investigated turbulators are more effective than classical ones, however, the pressure losses in the investigated turbulators are much higher. [ABSTRACT FROM AUTHOR]

In this work, dynamic mode decomposition (DMD) was applied as an algorithm for determining the natural frequency and damping ratio of viscoelastic lattice structures. The algorithm has been developed based on the Hankel alternative view of Koopman (HAVOK) and DMD. In general, the Hankel matrix is based on time-delay embedding, which is meant for the hidden variable in a time-series data. Vibration properties of a system could be then estimated from the eigenvalues of the approximated Koopman operator. Results of the proposed algorithm were firstly validated with those of the traditional discrete Fourier transform (DFT) approach and half-power bandwidth (HPBW) by using an analytical dataset of multi-modal spring-mass-damper system. Afterward, the algorithm was further used to analyze dynamic responses of viscoelastic lattice structures, in which data from both experimental and numerical finite element (FE) model were considered. It was found that the DMD-based algorithm could accurately estimate the natural frequencies and damping ratios of the examined structures. In particular, it is beneficial to any dataset with limited amounts of data, whereby experiments or data gathering processes are expensive. [ABSTRACT FROM AUTHOR]

Towards a sustainable future in construction, worldwide efforts aim to reduce cement use as a binder core material in concrete, addressing production costs, environmental concerns, and circular economy criteria. In the last decade, numerous studies have explored cement substitutes (e.g., fly ash, silica fume, clay-based materials, etc.) and methods to mimic the mechanical performance of cement by integrating polymeric meshes into their matrix. In this study, a systemic approach incorporating computer aid and biomimetics is utilized for the development of 3D-printed clay-based composite mortar reinforced with advanced polymeric bioinspired lattice structures, such as honeycombs and Voronoi patterns. These natural lattices were designed and integrated into the 3D-printed clay-based prisms. Then, these configurations were numerically examined as bioinspired lattice applications under three-point bending and realistic loading conditions, and proper Finite Element Models (FEMs) were developed. The extracted mechanical responses were observed, and a conceptual redesign of the bioinspired lattice structures was conducted to mitigate high-stress concentration regions and optimize the structures' overall mechanical performance. The optimized bioinspired lattice structures were also examined under the same conditions to verify their mechanical superiority. The results showed that the clay-based prism with honeycomb reinforcement revealed superior mechanical performance compared to the other and is a suitable candidate for further research. The outcomes of this study intend to further research into non-cementitious materials suitable for industrial and civil applications. [ABSTRACT FROM AUTHOR]

The design representations of lattice structures are fundamental to the development of computational design approaches. Current applications of lattice structures are characterized by ever-growing demand on computational resources to solve difficult optimization problems or generate large datasets, opting for the development of efficient design representations which offer a high range of possible design variants, while at the same time generating design spaces with attributes suitable for computational methods to explore. In response, the focus of this work is to propose a parametric design representation based on crystallographic symmetries and investigate its implications for the computational design of lattice structures. The work defines design rules to support the design of functionally graded structures using crystallographic symmetries such that the connectivity between individual members in a structure with varying geometry is guaranteed and investigates how to use the parametrization in the context of optimization. The results show that the proposed parametrization achieves a compact design representation to benefit the computational design process by employing a small number of design variables to control a broad range of complex geometries. The results also show that the design spaces based on the proposed parametrization can be successfully explored using a direct search-based method. [ABSTRACT FROM AUTHOR]

The utilization of lattice structure in engineering components by additive manufacturing (AM) is gaining attention due to its lightweight design, high strength-to-weight ratio, and effective material utilization. Producing holes in additively manufactured lattice structures with dimensional accuracy is challenging. In the current study, we fabricate near circular through-holes on deterministic lattice structured components fabricated by laser powder bed fusion by utilizing electric discharge machining (EDM). In the additively manufactured Inconel 718 (IN718) lattice structure, nodes are connected by strut leaving voids/pores amongst different nodal points. Due to EDM, the nodes at the boundary of the hole experience concentration plasma interaction, heating, and rapid cooling, which causes a substantial change in the microstructure. The selective removal of material from different nodal positions causes uncharacteristic recast layers, partial damages, and uncontrolled cracking of the struts. In the present study, we investigated and characterized the differential behaviour and mechanism of various surface integrity issues associated with the selective material removal of LPBF IN718 lattice structures and their elements (nodes and struts). [ABSTRACT FROM AUTHOR]

Lattice structures are a prime candidate for applications in the medical implant industry due to their versatile mechanical behaviour, which can be tailored to meet specific patient needs and reduce stress shielding, while enabling the natural flow of body fluids. In this work, the mechanical properties of metallic lattices made of five different unit cell types, Cubic (C), Truncated Octahedron (TO), Truncated Cubic (TC), Rhombicuboctahedron (RCO), and Rhombitruncated Cuboctahedron (RTCO), were evaluated under uniaxial compression at three different relative densities, 5%, 15%, and 45%. The evaluation was experimental, and it was compared with previous and new finite element simulations. Specimens for the experimental tests were fabricated in stainless steel 316L by laser powder bed fusion, and stress–strain curves were obtained for the different lattices. The combination of the test results with a critical interpretation of the deformation mechanisms allowed us to confirm that two unit cell types, TO and RTCO, are stable for the whole range of relative densities evaluated. The other three unit cells exhibit more unpredictable behaviour, either due to manufacturing defects or limitations, or because their unstable compression behaviour leads to bucking. For these reasons, TO and RTCO unit cell types are mechanically more adequate for applications in the medical implant industry. [ABSTRACT FROM AUTHOR]

The advancement in additive manufacturing has significantly expanded the use of lattice structures in many engineering fields. Titanium diamond lattice structures, produced by a direct metal laser sintering process, were experimentally investigated. Two cell sizes were selected at five different relative densities. Morphological analysis was conducted by digital microscopy. The compressive tests and digital image correlation technique allowed the evaluation of elastic moduli to be used in the Gibson–Ashby model. Failure mechanisms of the structures have been analysed by digital image correlation, which represents a promising technique for strain evaluation of such structures. A non-linear finite element model of the lattice structures was developed and validated using the experimental data. The analysis of the results highlights the good mechanical properties of the Ti6Al4V alloy lattice structures. [ABSTRACT FROM AUTHOR]

The robotic arm is one of the vital components of robot assembly. The purpose of the robotic arm is to transmit power and conduct the desired motion, i.e., translation or rotation. Robotic limbs are designed and constructed to execute certain tasks with a high degree of speed, accuracy, and efficiency. This research focuses on to enhancing the strength-to-weight ratio of robotic arm using certain techniques of additive manufacturing, i.e., topology optimization and lattice structure. Employing the finite element analysis, the impact of weight reduction optimization on structural parameters such as stress and deformation in the current design is assessed using ANSYS R18.1 for FE analysis and Creo parametric 7.0 design software for computer-aided design modeling. Observations reveal that the 0.5 and .4 scale lattice structure designs have deformation of 0.01453mm and 0.01453mm respectively though the generic design has 0.01043mm deformation. Notably, the 0.5 scale lattice of the robotic arm exhibits a 31.08% higher equivalent stress than the generic design with 29.3%. reduction in mass of the robotic arm. These findings highlight the efficacy of lattice structures for optimizing the robotic arm's performance, contributing to advancements in power-efficient robot assembly processes. [ABSTRACT FROM AUTHOR]

Lattice structures have gained attention in engineering due to their lightweight properties. However, the complex geometry of lattice structures and the high melting temperature of metals present significant manufacturing challenges for the large-scale fabrication of these structures. Direct Energy Deposition (DED) methods, such as the Wire Arc Additive Manufacturing (WAAM) technique, appear to be an interesting solution for overcoming these limitations. This study provides a detailed analysis of the manufacturing process of carbon steel lattice structures with auxetic geometry. The study includes thermal analysis using infrared thermography, microstructural characterization through metallography, and mechanical evaluation via hardness and mechanical testing. The findings reveal the significant impact of heat input, thermal cycles, and deposition sequence on the morphology and mechanical properties of the lattice structures. Fast thermal cycles are related to areas with higher hardness values, smaller strut diameters, and porous formations, which shows that controlling heat input and heat dissipation is crucial for optimizing the properties of lattice structures produced using WAAM. [ABSTRACT FROM AUTHOR]

Additively manufactured lattice structures are extensively utilized because of their unique characteristics, including lightweight design, high energy absorption capabilities, and exceptional specific strength. This study focuses on accurately simulating the dynamic mechanical behavior of AlSi10Mg lattice structures produced using selective laser melting (SLM). A series of experimental studies has been conducted to establish the parameters of the J–C hardening and damage model for additively manufactured AlSi10Mg alloys. The lattice structures, featuring face-centered cubic (FCC) and diamond topologies with a 25% designed relative density, underwent scanning electron microscopy (SEM) for geometrical precision assessment. Dynamic compressive behavior was investigated via split Hopkinson pressure bar (SHPB) tests. Numerical simulations in Ls-Dyna, utilizing the identified J–C parameters, were employed to replicate SHPB tests. Findings indicate that the specific strength and the specific energy absorption values of FCC lattice samples have higher than those of diamond samples at strain rates of 750 and 1100 s−1. While the overall strains and deformation modes were well predicted by numerical analyzes, a deeper insight into local stress concentrations under dynamic loads was achieved. Consequently, the obtained J–C model parameters offer valuable insight into characterizing the dynamic behavior of AlSi10Mg lattice structures produced by SLM. [ABSTRACT FROM AUTHOR]

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 to examine 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 interconnectivity, 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. [ABSTRACT FROM AUTHOR]

Numerical techniques are developed to generate innovative lightweight designs, difficult to obtain with traditional product manufacturing technologies. The use of advanced engineering design software makes it possible to generate un‐conventional geometries, combining a standard density‐based topology optimization approach with lattice structure‐based methods. Deep knowledge of modeling aspects is required to improve the topology optimization processes currently performed in aerospace applications, as well as to achieve design solutions suitably prepared for additive manufacturing technologies. In the present work, algorithms based on solid isotropic material with penalization (SIMP) method are used to reduce the weight of parts by removing unnecessary material from the initial part design. Moreover, the integration of lattice structures in the topology optimization procedures allows for a further part weight reduction offering the possibility of exploiting the potentials of 3D printing in the fabrication of complex geometries. [ABSTRACT FROM AUTHOR]

Lattice structures have emerged as promising materials for aerospace structure applications due to their high strength-to-weight ratios, customizable properties, and efficient use of materials. These properties make them attractive for use in anti-ice systems, where lightweight and heat exchange are essential. This paper presents an extensive experimental investigation into mechanical compression properties of lattice trusses fabricated from AlSi10Mg powder alloy, a material commonly used in casted aerospace parts. The truss structures were manufactured using the additive manufacturing selective laser melting technique and were subjected to uniaxial compressive loading to assess their performance. The results demonstrate that AlSi10Mg lattice trusses exhibit remarkable compressive strength with strong correlations depending upon both topology and cells' parameters setup. The findings described highlight the potential of AlSi10Mg alloy as a promising material for custom truss fabrication, offering customizable cost-effective and lightweight solutions for the aerospace market. This study also emphasizes the role of additive manufacturing in producing complex structures with pointwise-tailored mechanical properties. [ABSTRACT FROM AUTHOR]

Bone microstructures or scaffolds mimicking natural bone characteristics find widespread applications in bone tissue engineering (BTE). To accurately replicate a personalized bone structure, we developed a heterogeneous scaffold by combining medical image data with the octree adaptive subdivision technique. The transformations between Hounsfield units (HU)-strength and strength-lattice features were implemented for mapping bone information to the scaffold. Initially, HU values from computed tomography (CT) images were smoothly converted into corresponding strengths through a rational Bezier curve. Then, these strengths were further translated into the features of lattice structures, specifically the strut diameter and subdivision level. The novel concept of adaptive octree subdivision, executed on the lattices, allows for controlling bone porosity and mechanical property even at local levels. As a result, a personalized heterogeneous scaffold accurately simulating natural bone structure was designed and manufactured for bone grafting application on a 3D-printed alveolar model. The scaffold has an outer cortical bone layer capable of withstanding pressures of up to 208.2 MPa, while the inner cancellous bone exhibits a high porosity ranging from 77.6 % to 93.6 %. The research provides an elegant yet effective approach to the generation of bone microstructures, opening up practical BTE applications.