Laser additive manufacturing of aluminum-based stochastic and nonstochastic cellular materials.

• Additive manufacturing in Al-based cellular materials is primarily examined. • Manufacturability of Al-based cellular materials using LPBF and DED is showcased. • Significant AM process parameters and unit cells adopted are thoroughly analyzed. • The most preferred feedstock includes AlSi10Mg, AlSi12Mg, and Al 6061 powders. • Microstructures play a key role in the mechanics of Al-based cellular materials. • Imperfections in lattice structures significantly impact on their performance. Cellular materials are gaining significant attention in product development due to their unique characteristics, offering superior mechanical performance and functionalities while minimizing material usage and environmental impact. This review article provides an overview of additive manufacturing (AM) technologies for producing aluminum-based cellular materials, focusing on laser AM techniques including laser powder bed fusion and directed energy deposition. The article explores the classification of cellular materials into stochastic foams and nonstochastic lattice structures and discusses conventional manufacturing methods and their limitations. It then examines the emergence of AM as a solution to these limitations, offering advantages such as design customization and optimization, shorter lead times, and the ability to manufacture complex architectures. The article highlights the current research status on AM of cellular materials including lattice shapes, design methods, and AM techniques. It further addresses the current status of AM of aluminum alloys, emphasizing the challenges and advances in producing aluminum-based cellular materials using AM. [ABSTRACT FROM AUTHOR]