Design Exploration of Biomorphic Freeform Unit Cells for Additively Manufactured Lattice Structures Under Compressive Loads

Thallemer, Axel; Kostadinov, Aleksandar; Fam, Abel; Teo, Alex Quok An

doi:10.21278/idc.2018.0200

Cited by 3 publications

(3 citation statements)

References 28 publications

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“…Habib et al [ 25 ] compared the performance of octagonal lattices (cell size 10 mm) built by multi-jet fusion (MJF) and FFF, reporting that the MJF fabricated samples had better properties than the FFF samples. Manufacturing of polymer lattice structures by other AM methods has also been reported, including stereolithography [ 26 , 27 ], multi-jet fusion [ 28 ], and laser sintering [ 29 , 30 ], but little information is reported regarding manufacturability. Stereolithography and LS are capable of producing small features (strut/wall thickness 0.4–0.6 mm) while values reported for multi-jet fusion are larger (cell size 10 mm; strut diameter > 1.13 mm).…”

Section: Introductionmentioning

confidence: 99%

Manufacturing and Characterization of 3D Miniature Polymer Lattice Structures Using Fused Filament Fabrication

et al. 2021

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The potential of additive manufacturing to produce architected lattice structures is remarkable, but restrictions imposed by manufacturing processes lead to practical limits on the form and dimension of structures that can be produced. In the present work, the capabilities of fused filament fabrication (FFF) to produce miniature lattices were explored, as they represent an inexpensive option for the production of polymer custom-made lattice structures. First, fused filament fabrication design guidelines were tested to assess their validity for miniature unit cells and lattice structures. The predictions were contrasted with the results of printing tests, showing some discrepancies between expected outcomes and resulting printed structures. It was possible to print functional 3D miniature open cell polymer lattice structures without support, even when some FFF guidelines were infringed, i.e., recommended minimum strut thickness and maximum overhang angle. Hence, a broad range of lattice structures with complex topologies are possible, beyond the cubic-type cell arrangements. Nevertheless, there are hard limits in 3D printing of miniature lattice structures. Strut thickness, length and orientation were identified as critical parameters in miniature lattice structures. Printed lattices that did not fully comply with FFF guidelines were capable of bearing compressive loads, even if surface quality and accuracy issues could not be fully resolved. Nevertheless, 3D printed FFF lattice structures could represent an improvement compared to other additive manufacturing processes, as they offer good control of cell geometry, and does not require additional post-processing.

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Section: Introductionmentioning

confidence: 99%

Manufacturing and Characterization of 3D Miniature Polymer Lattice Structures Using Fused Filament Fabrication

et al. 2021

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“…During the last decade, special attention has been given to the development of design and optimization methods for lattice structures [ 6 , 9 , 10 , 11 , 12 ]. Moreover, the fabrication and testing for a wide variety of lattices fabricated using different AM processes have been reported, including material extrusion (ME) [ 13 , 14 , 15 , 16 , 17 ], vat photopolymerization (VP) [ 18 , 19 , 20 , 21 , 22 ], jet fusion (JF) [ 23 , 24 , 25 ], and selective laser sintering (SLS) [ 21 , 26 , 27 , 28 ].…”

Section: Introductionmentioning

confidence: 99%

A Comparison of Miniature Lattice Structures Produced by Material Extrusion and Vat Photopolymerization Additive Manufacturing

2021

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In this paper, we study the capabilities of two additive manufacturing technologies for the production of lattice structures, namely material extrusion and vat photopolymerization additive manufacturing. A set of polymer lattice structures with diverse unit cell types were built using these additive manufacturing methods and tested under compression. Lattice structures built using material extrusion had lower accuracy and a lower relative density caused by the air gaps between layers, but had higher elastic moduli and larger energy absorption capacities, as a consequence of both the thicker struts and the relatively larger strength of the feedstock material. Additionally, the deformation process in lattices was analyzed using sequential photographs taken during the compression tests, evidencing larger differences according to the manufacturing process and unit-cell type. Both additive manufacturing methods produced miniature lattice structures with similar mechanical properties, but vat polymerization should be the preferred option when high geometrical accuracy is required. Nevertheless, as the solid material determines the compressive response of the lattice structure, the broader availability of feedstock materials gives an advantage to material extrusion in applications requiring stiffer structures or with higher energy absorption capabilities.

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“…Thus, the characterization of a multitude of lattice configurations manufactured using diverse AM methods such as fused deposition modeling [ 7 , 10 , 11 , 12 , 13 ], stereolithography [ 14 , 15 , 16 ], jet fusion [ 17 , 18 , 19 ], and selective laser sintering [ 20 , 21 ] is currently a very active topic in research, in addition to the development of diverse analytical and numerical methods for the design of lattice structures [ 22 , 23 , 24 , 25 ].…”

Section: Introductionmentioning

confidence: 99%

Influence of Geometric and Manufacturing Parameters on the Compressive Behavior of 3D Printed Polymer Lattice Structures

et al. 2021

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Fused deposition modeling represents a flexible and relatively inexpensive alternative for the production of custom-made polymer lattices. However, its limited accuracy and resolution lead to geometric irregularities and poor mechanical properties when compared with the digital design. Although the link between geometric features and mechanical properties of lattices has been studied extensively, the role of manufacturing parameters has received little attention. Additionally, as the size of cells/struts nears the accuracy limit of the manufacturing process, the interaction between geometry and manufacturing parameters could be decisive. Hence, the influence of three geometric and two manufacturing parameters on the mechanical behavior was evaluated using a fractional factorial design of experiments. The compressive behavior of two miniature lattice structures, the truncated octahedron and cubic diamond, was evaluated, and multilinear regression models for the elastic modulus and plateau stress were developed. Cell size, unit cell type, and strut diameter had the largest impact on the mechanical properties, while the influence of feedstock material and layer thickness was very limited. Models based on factorial design, although limited in scope, could be an effective tool for the design of customized lattice structures.

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Design Exploration of Biomorphic Freeform Unit Cells for Additively Manufactured Lattice Structures Under Compressive Loads

Cited by 3 publications

References 28 publications

Manufacturing and Characterization of 3D Miniature Polymer Lattice Structures Using Fused Filament Fabrication

Manufacturing and Characterization of 3D Miniature Polymer Lattice Structures Using Fused Filament Fabrication

A Comparison of Miniature Lattice Structures Produced by Material Extrusion and Vat Photopolymerization Additive Manufacturing

Influence of Geometric and Manufacturing Parameters on the Compressive Behavior of 3D Printed Polymer Lattice Structures

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