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<p>The fabrication of metallic lattice materials via Laser-Powder Bed Fusion (L-PBF) often suffers from geometric deviations that emerge between their nominal and as-built architectures caused by manufacturing-induced imperfections. The mismatches, including irregular strut cross-sections and node distortions, significantly impact both the geometric fidelity and mechanical performance of the final lattice component. This study addresses these challenges by introducing a systematic, design-driven compensation framework that enhances geometric precision without the need to alter the process parameters. Its efficacy is demonstrated through a representative cubic lattice, targeting sub-unital geometric elements, such as fillet radii, strut thicknesses, and cross-sectional profiles, accounting for multiple build orientations and part scales. Leveraging an extensive dataset obtained via a rapid and cost-effective stereomicroscopic analysis, the results demonstrate a significant reduction in the as-designed/as-built geometric mismatch. This framework can potentially serve as a promising step towards more robust design strategies for the application of strut-based lattices in industrial real-life applications.</p> Graphical abstract <p></p>

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Mitigating manufacturing defects in laser-powder bed fusion: a design-led compensation framework for truss-based metallic lattices

  • 期刊论文

  • 发表日期：

    2025年9月13日

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  • S. Murchio,
  • M. Benedetti,
  • M. Dallago,
  • S. Raghavendra,
  • G. Zappini,
  • D. Pasini

摘要

The fabrication of metallic lattice materials via Laser-Powder Bed Fusion (L-PBF) often suffers from geometric deviations that emerge between their nominal and as-built architectures caused by manufacturing-induced imperfections. The mismatches, including irregular strut cross-sections and node distortions, significantly impact both the geometric fidelity and mechanical performance of the final lattice component. This study addresses these challenges by introducing a systematic, design-driven compensation framework that enhances geometric precision without the need to alter the process parameters. Its efficacy is demonstrated through a representative cubic lattice, targeting sub-unital geometric elements, such as fillet radii, strut thicknesses, and cross-sectional profiles, accounting for multiple build orientations and part scales. Leveraging an extensive dataset obtained via a rapid and cost-effective stereomicroscopic analysis, the results demonstrate a significant reduction in the as-designed/as-built geometric mismatch. This framework can potentially serve as a promising step towards more robust design strategies for the application of strut-based lattices in industrial real-life applications.

Graphical abstract