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Abstract Three-dimensional lattices have applications across a range of fields including structural lightweighting, impact absorption and biomedicine. In this work, lattices based on triply periodic minimal surfaces were produced by polymer additive manufacturing and examined with a combination of experimental and computational methods. This investigation elucidates their deformation mechanisms and provides numerical parameters crucial in establishing relationships between their geometries and mechanical performance. Three types of lattice were examined, with one, known as the primitive lattice, being found to have a relative elastic modulus over twice as large as those of the other two. The deformation process of the primitive lattice was also considerably different from those of the other two, exhibiting strut stretching and buckling, while the gyroid and diamond lattices deformed in a bending dominated manner. Finite element predictions of the stress distributions in the lattices under compressive loading agreed with experimental observations. These results can be used to create better informed lattice designs for a range of mechanical and biomedical applications. Graphical abstract Image 1 Highlights • Manufactured and tested lattice structures based on triply periodic minimal surfaces. • Lattices with equivalent masses deform differently depending on their cell geometry. • High stiffness seen for the structure which showed buckling and low failure strain. • Determined Gibson-Ashby factors enabling the design of optimised latticed components. [ABSTRACT FROM AUTHOR]

Metal components with applications across a range of industrial sectors can be manufactured by selective laser melting (SLM). A particular strength of SLM is its ability to manufacture components incorporating periodic lattice structures not realisable by conventional manufacturing processes. This enables the production of advanced, functionally graded, components. However, for these designs to be successful, the relationships between lattice geometry and performance must be established. We do so here by examining the mechanical behaviour of uniform and graded density SLM Al-Si10-Mg lattices under quasistatic loading. As-built lattices underwent brittle collapse and non-ideal deformation behaviour. The application of a microstructure-altering thermal treatment drastically improved their behaviour and their capability for energy absorption. Heat-treated graded lattices exhibited progressive layer collapse and incremental strengthening. Graded and uniform structures absorbed almost the same amount of energy prior to densification, 6.3 ± 0.2 MJ/m 3 and 5.7 ± 0.2 MJ/m 3 , respectively, but densification occurred at around 7% lower strain for the graded structures. Several characteristic properties of SLM aluminium lattices, including their effective elastic modulus and Gibson-Ashby coefficients, C 1 and α , were determined; these can form the basis of new design methodologies for superior components in the future. [ABSTRACT FROM AUTHOR]

Significant weight savings in parts can be made through the use of additive manufacture (AM), a process which enables the construction of more complex geometries, such as functionally graded lattices, than can be achieved conventionally. The existing framework describing the mechanical properties of lattices places strong emphasis on one property, the relative density of the repeating cells, but there are other properties to consider if lattices are to be used effectively. In this work, we explore the effects of cell size and number of cells, attempting to construct more complete models for the mechanical performance of lattices. This was achieved by examining the modulus and ultimate tensile strength of latticed tensile specimens with a range of unit cell sizes and fixed relative density. Understanding how these mechanical properties depend upon the lattice design variables is crucial for the development of design tools, such as finite element methods, that deliver the best performance from AM latticed parts. We observed significant reductions in modulus and strength with increasing cell size, and these reductions cannot be explained by increasing strut porosity as has previously been suggested. We obtained power law relationships for the mechanical properties of the latticed specimens as a function of cell size, which are similar in form to the existing laws for the relative density dependence. These can be used to predict the properties of latticed column structures comprised of body-centred-cubic (BCC) cells, and may also be adapted for other part geometries. In addition, we propose a novel way to analyse the tensile modulus data, which considers a relative lattice cell size rather than an absolute size. This may lead to more general models for the mechanical properties of lattice structures, applicable to parts of varying size. [ABSTRACT FROM AUTHOR]