Architected Materials for Additive Manufacturing: A Comprehensive Review

Abstract

One of the main advantages of Additive Manufacturing (AM) is the ability to produce topologically optimized parts with high geometric complexity. In this context, a plethora of architected materials was investigated and utilized in order to optimize the 3D design of existing parts, reducing their mass, topology-controlling their mechanical response, and adding remarkable physical properties, such as high porosity and high surface area to volume ratio. Thus, the current re-view has been focused on providing the definition of architected materials and explaining their main physical properties. Furthermore, an up-to-date classification of cellular materials is presented containing all types of lattice structures. In addition, this research summarized the developed methods that enhance the mechanical performance of architected materials. Then, the effective mechanical behavior of the architected materials was investigated and compared through the existing literature. Moreover, commercial applications and potential uses of the architected materials are presented in various industries, such as the aeronautical, automotive, biomechanical, etc. The objectives of this comprehensive review are to provide a detailed map of the existing architected materials and their mechanical behavior, explore innovative techniques for improving them and highlight the comprehensive advantages of topology optimization in industrial applications utilizing additive manufacturing and novel architected materials.

Comparative Analysis of Bone Ingrowth in 3D-Printed Titanium Lattice Structures with Different Patterns

“…In terms of 3D-printer-fabricated lattice structures, there are mainly morphological, mechanical, finite element studies, where the authors investigated the strength of different shapes [ 2 , 7 , 34 , 35 , 36 , 37 ]. Several authors have studied the effects of pore size on bone ingrowth [ 11 , 12 , 13 , 14 , 15 , 16 , 17 , 18 , 19 , 20 , 21 , 22 , 23 ].…”

Mechanical Behavior and Material Modeling of Fused Filament Fabricated PEEK based on TPMS Lattices: A Comparative Study

“…Metamaterials, architectured cellular solids resembling natural porous structures, have revolutionized material science and engineering because of their unique ability to simultaneously meet conflicting requirements, such as achieving a balance between lightweightness and strength [1]. Architectured cellular solids can be categorized based on the unit cell's geometry and arrangement into stochastic (foams), periodic (lattices), and pseudoperiodic [2,3]. Stochastic (foams) materials refer to materials without predictably repeating unit cells, such as natural, voronoi, and delaunay [4].…”

DDSM: Design-Oriented Dual-Scale Shape-Material Model for Lattice Material Components

“…Conventional CAD models are not efficient at representing lattice structures [ 5 ]. Since the manufacturing of lattice structures is mostly achieved by additive manufacturing [ 6 ], about 80% of lattice files are stored in stereolithography format (STL) [ 7 ]. However, the triangular mesh-based CAD model can only reflect the geometric information of the components discretely, ignoring the dual-material information (i.e., homogenized equivalent materials and manufacturing materials).…”