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<p>The powder bed fusion-based laser sintering process enables the fabrication of lattice structures consisting of periodic cells formed by interconnected struts, tailoring the mechanical response based on the specific application. However, the performance of the fabricated components is highly influenced by multiple factors, including the building direction, part geometry, unit cell configuration, strut dimensions, the laser sintering machine employed, the initial material, and the process parameters. Therefore, this study investigated six different lattice structures designed through the primitive-based method and analyzed with compression and tensile tests to identify the mechanical properties and the failure mode. Moreover, a numerical model is proposed to reproduce the compressive behavior of the most distinctive lattice structure, satisfying the requirement of layer-by-layer failure mode for improved energy absorption capabilities. Both tensile and compression tests suggest that the body-centered cubic geometry is the best candidate, reaching the same deformation and doubling the energy absorption efficiency compared to the bulk sample. The numerical model accurately predicts the failure mode of the identified lattice structure, with an average error in estimating the energy absorption efficiency lower than 4%. </p>

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Enhanced mechanical performance of laser sintered lattice structures: insights from experimental testing and finite element analysis

  • 期刊论文

  • 发表日期：

    2025年5月15日

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  • Vittorio Villani,
  • Alfio Scuderi,
  • Gennaro Salvatore Ponticelli,
  • Stefano Guarino

摘要

The powder bed fusion-based laser sintering process enables the fabrication of lattice structures consisting of periodic cells formed by interconnected struts, tailoring the mechanical response based on the specific application. However, the performance of the fabricated components is highly influenced by multiple factors, including the building direction, part geometry, unit cell configuration, strut dimensions, the laser sintering machine employed, the initial material, and the process parameters. Therefore, this study investigated six different lattice structures designed through the primitive-based method and analyzed with compression and tensile tests to identify the mechanical properties and the failure mode. Moreover, a numerical model is proposed to reproduce the compressive behavior of the most distinctive lattice structure, satisfying the requirement of layer-by-layer failure mode for improved energy absorption capabilities. Both tensile and compression tests suggest that the body-centered cubic geometry is the best candidate, reaching the same deformation and doubling the energy absorption efficiency compared to the bulk sample. The numerical model accurately predicts the failure mode of the identified lattice structure, with an average error in estimating the energy absorption efficiency lower than 4%.