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<p>The compressive mechanical behavior of additively manufactured truss lattice structures is governed by both unit-cell topology and manufacturing direction. In this study, the combined influence of these factors is experimentally investigated using three truss lattice configurations with different levels of directional connectivity, denoted as DCS1, DCS2, and DCS3. All specimens were fabricated from AlSi10Mg using laser powder bed fusion at comparable relative densities and tested under quasi-static compression. The results reveal that unit-cell topology is the primary determinant of compressive stiffness, strength, and deformation behavior, while manufacturing direction modulates the magnitude of mechanical performance in a topology-dependent manner. Bending-dominated configurations with low directional connectivity exhibit lower stiffness but stable and robust deformation behavior, whereas stretch-enhanced configurations achieve higher stiffness and strength but show pronounced sensitivity to manufacturing direction and process-induced imperfections. Mixed-connectivity configurations display intermediate mechanical characteristics reflecting combined bending and axial load transfer mechanisms. Full-field strain measurements obtained by digital image correlation demonstrate distinct topology-dependent deformation and failure modes and reveal that configurations dominated by axial load transfer exhibit greater specimen-to-specimen variability. These findings clarify that the effect of manufacturing direction on mechanical performance cannot be interpreted independently of unit-cell topology. This interaction-based experimental framework represents the central novelty of the present work, as such topology–orientation coupling has not been systematically investigated in LPBF-fabricated open-frame truss lattices at controlled relative densities.</p>

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Topology–Manufacturing Interaction in Lightweight Truss Lattice Structures Fabricated by Additive Manufacturing

  • 期刊论文

  • 发表日期：

    2026年4月7日

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  • Jeongho Choi

摘要

The compressive mechanical behavior of additively manufactured truss lattice structures is governed by both unit-cell topology and manufacturing direction. In this study, the combined influence of these factors is experimentally investigated using three truss lattice configurations with different levels of directional connectivity, denoted as DCS1, DCS2, and DCS3. All specimens were fabricated from AlSi10Mg using laser powder bed fusion at comparable relative densities and tested under quasi-static compression. The results reveal that unit-cell topology is the primary determinant of compressive stiffness, strength, and deformation behavior, while manufacturing direction modulates the magnitude of mechanical performance in a topology-dependent manner. Bending-dominated configurations with low directional connectivity exhibit lower stiffness but stable and robust deformation behavior, whereas stretch-enhanced configurations achieve higher stiffness and strength but show pronounced sensitivity to manufacturing direction and process-induced imperfections. Mixed-connectivity configurations display intermediate mechanical characteristics reflecting combined bending and axial load transfer mechanisms. Full-field strain measurements obtained by digital image correlation demonstrate distinct topology-dependent deformation and failure modes and reveal that configurations dominated by axial load transfer exhibit greater specimen-to-specimen variability. These findings clarify that the effect of manufacturing direction on mechanical performance cannot be interpreted independently of unit-cell topology. This interaction-based experimental framework represents the central novelty of the present work, as such topology–orientation coupling has not been systematically investigated in LPBF-fabricated open-frame truss lattices at controlled relative densities.