Architected cellular materials: A review on their mechanical properties towards fatigue-tolerant design and fabrication

Benedetti, M.; Plessis, Anton du; Ritchie, Robert O.; Dallago, Michele; Razavi, Seyed Mohammad Javad; Berto, Filippo

doi:10.1016/j.mser.2021.100606

Cited by 455 publications

(206 citation statements)

References 248 publications

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“…In cellular solids, relative density is measured as the ratio of the density of the cellular material to the density of the solid constituent material and functions as the complement to porosity. [ 7 ] The significant porosity of cellular materials results in low relative densities, which range based on the underlying solid material. Relative densities of porous solids are typically >0.3, whereas polymeric foams display relative densities over the range 0.05–0.2.…”

Section: Measurements and Characterization Of Cancellous Bone Microarchitecturementioning

confidence: 99%

“…[ 103 ] This finding demonstrated that fatigue behavior is dependent not only on porosity but also on microarchitecture. [ 7 ] The bone community normalizes by Young's modulus, because each specimen is unique, making it difficult to specify the plateau strength in fatigue studies that do not load to uniaxial failure. The approaches are analogous, however, because Young's modulus is highly correlated with strength.…”

Section: Relationships Between Cancellous Microarchitecture and Mechanical Propertiesmentioning

confidence: 99%

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Characterization of Ultralow‐Density Cellular Solids: Lessons from 30 years of Bone Biomechanics Research

2021

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Recent advances in manufacturing of microarchitectured materials have begun to overcome longstanding challenges in materials engineering to create porous materials that are simultaneously lightweight, strong, stiff, and flaw-tolerant. Novel manufacturing techniques now enable materials with lattice structures to be constructed at lower densities with higher resolutions than previously possible. In parallel, extensive materials characterization of lightweight porous biological materials-such as bone, wood, bamboo, and sponges-has enabled identification of common strategies to achieve high specific stiffness, strength, and impact energy absorption. [1,2] Although the details of the structures of these materials vary considerably, these key mechanical properties arise from two common microstructural features: 1) a multiscale hierarchical structure that spans the nano-to the microscale (Figure 2) and 2) tolerance of flaws below a critical characteristic material length scale. [3] Materials engineers are now poised to combine novel manufacturing techniques with biomimetic materials design strategies to develop synthetic engineering materials with properties that were previously unachievable.Understanding the load-bearing properties of these novel low-density microarchitectured materials is necessary to translate them to engineering design applications. In general, the microscale properties of the solid constituent material are known, but the millimeter-scale mechanical properties of the porous cellular solid are unknown and require assessment. Although standard experimental and computational analyses are adequate for high-and medium-density microarchitectured materials, a substantial literature from the bone biomechanics community demonstrates that 1) standard approaches can result in large errors in characterization of low-and ultralow-density porous materials, and 2) adjustments to experimental and computational methods for low-and ultralow-density porous materials improve accuracy and precision of these approaches.Solutions from the bone biomechanics community are applicable to low-density synthetic materials. We aim to offer information on the relationship between microarchitecture and mechanical properties in low-density bone that is primarily reported in the medical literature, often in the context of bone biology or clinical research and not summarized in a manner that is immediately useful to materials scientists. The goal of this article is to provide a review of the past 30 years of cancellous bone biomechanics with the intent of presenting an example of methodologies for characterizing the structure and mechanical performance of a low-density porous microarchitectured material. In particular, we answer three key questions: 1

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Section: Measurements and Characterization Of Cancellous Bone Microarchitecturementioning

confidence: 99%

Section: Relationships Between Cancellous Microarchitecture and Mechanical Propertiesmentioning

confidence: 99%

Characterization of Ultralow‐Density Cellular Solids: Lessons from 30 years of Bone Biomechanics Research

2021

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“…For example, a highly skilled workforce is required, file formats for exchanging the data related to the AM workflow need enhancements [8,9], and design methods and tools for complex structures, multi-material parts, and functionally graded materials need to be improved [10,11]. The concerns over the structural integrity of these complex parts require static and dynamic mechanical characterization [12,13]; also, experimental tests help to mechanically characterize the materials, skilled workforce is required, file formats for exchanging the data related to the AM workflow need enhancements [8,9], and design methods and tools for complex structures, multi-material parts, and functionally graded materials need to be improved [10,11]. The concerns over the structural integrity of these complex parts require static and dynamic mechanical characterization [12,13]; also, experimental tests help to mechanically characterize the materials, and the obtained information is used in numerical simulations to predict the different mechanical behavior between the products obtained through additive manufacturing and the ones obtained by traditional techniques of material subtraction [14,15].…”

Section: Introductionmentioning

confidence: 99%

“…The concerns over the structural integrity of these complex parts require static and dynamic mechanical characterization [12,13]; also, experimental tests help to mechanically characterize the materials, skilled workforce is required, file formats for exchanging the data related to the AM workflow need enhancements [8,9], and design methods and tools for complex structures, multi-material parts, and functionally graded materials need to be improved [10,11]. The concerns over the structural integrity of these complex parts require static and dynamic mechanical characterization [12,13]; also, experimental tests help to mechanically characterize the materials, and the obtained information is used in numerical simulations to predict the different mechanical behavior between the products obtained through additive manufacturing and the ones obtained by traditional techniques of material subtraction [14,15]. More, dedicated qualification standards for AM are needed to guarantee an adequate quality of the printed parts [16,17] and their representation in 2D drawings [18].…”

Section: Introductionmentioning

confidence: 99%

An Optimization Workflow in Design for Additive Manufacturing

et al. 2021

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Additive Manufacturing (AM) brought a revolution in parts design and production. It enables the possibility to obtain objects with complex geometries and to exploit structural optimization algorithms. Nevertheless, AM is far from being a mature technology and advances are still needed from different perspectives. Among these, the literature highlights the need of improving the frameworks that describe the design process and taking full advantage of the possibilities offered by AM. This work aims to propose a workflow for AM guiding the designer during the embodiment design phase, from the engineering requirements to the production of the final part. The main aspects are the optimization of the dimensions and the topology of the parts, to take into consideration functional and manufacturing requirements, and to validate the geometric model by computer-aided engineering software. Moreover, a case study dealing with the redesign of a piston rod is presented, in which the proposed workflow is adopted. Results show the effectiveness of the workflow when applied to cases in which structural optimization could bring an advantage in the design of a part and the pros and cons of the choices made during the design phases were highlighted.

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“…Compared with other metallic AM techniques, laser powder bed fusion (LPBF) is well-suited for fabricating the TPMS structures with high resolution and good dimensional accuracy [ 2 ]. Generally, most LPBF machines hold a typical accuracy of ±50 μm [ 14 ] and a minimum feature size of 200 μm [ 15 ]. The printed components with TWS feature design always show an increase in the relative density as the adjacent powder melts and sticks to the surface [ 16 ].…”

Section: Introductionmentioning

confidence: 99%

Achieving Triply Periodic Minimal Surface Thin-Walled Structures by Micro Laser Powder Bed Fusion Process

Ding

Song

2021

Micromachines

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Recently, triply periodic minimal surface (TPMS) lattice structures have been increasingly employed in many applications, such as lightweighting and heat transfer, and they are enabled by the maturation of additive manufacturing technology, i.e., laser powder bed fusion (LPBF). When the shell-based TPMS structure’s thickness decreases, higher porosity and a larger surface-to-volume ratio can be achieved, which results in an improvement in the properties of the lattice structures. Micro LPBF, which combines finer laser beam, smaller powder, and thinner powder layer, is employed in this work to fabricate the thin-walled structures (TWS) of TPMS lattice by stainless steel 316 L (SS316L). Utilizing this system, the optimal parameters for printing TPMS-TWS are explored in terms of densification, smoothness, limitation of thickness, and dimensional accuracy. Cube samples with 99.7% relative density and a roughness value of 2.1 μm are printed by using the energy density of 100 J/mm3. Moreover, a thin (100 μm thickness) wall structure can be fabricated through optimizing parameters. Finally, the TWS samples with various TPMS structures are manufactured to compare their heat dissipation capability. As a result, TWS sample of TPMS lattice exhibits a larger temperature gradient in the vertical direction compared to the benchmark sample. The steady-state temperature of the sample base presents a 7 K decrease via introducing TWS.

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Architected cellular materials: A review on their mechanical properties towards fatigue-tolerant design and fabrication

Cited by 455 publications

References 248 publications

Characterization of Ultralow‐Density Cellular Solids: Lessons from 30 years of Bone Biomechanics Research

Characterization of Ultralow‐Density Cellular Solids: Lessons from 30 years of Bone Biomechanics Research

An Optimization Workflow in Design for Additive Manufacturing

Achieving Triply Periodic Minimal Surface Thin-Walled Structures by Micro Laser Powder Bed Fusion Process

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