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<p>This work introduces a thin-walled, modular flexible structure, the Highly Deformable Structure (HDS), specifically engineered to exhibit bending-dominated behavior and a deployable mechanism, enabling large deformations, high energy absorption, and superior flexibility. HDS specimens were fabricated through Laser Powder Bed Fusion (LPBF) process using three different materials: SS316L, AlSi10Mg and NiTi. The study combined morphological analyses and mechanical characterizations to provide a comprehensive assessment of their performance. The results demonstrate that the HDS geometry accommodates significant deformations without structural failure, confirming the robustness of the design. Dynamic analyses conducted at 2&#xa0;Hz showed that, among the tested alloys, NiTi exhibited the highest damping capacity, with a <i>tanδ</i> of 0.035 at 1% deformation amplitude, at a mean force of 20&#xa0;N and at 5&#xa0;°C (corresponding to austenite start temperature <i>A</i><sub><i>s</i></sub>). In comparison, SS316L and AlSi10Mg HDS cells also showed excellent dynamic response within the plastic regime at strain below 0.5%. Furthermore, the NiTi-based HDS benefits from shape memory effect, recovering over 50% of the applied deformation, which makes it particularly suitable for impact-resistance applications. These findings highlight the potential of LPBF in developing next-generation metallic components with tunable deformability, enabling advances in load bearing, damping and energy absorbing systems.</p>

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SS316L, AlSi10Mg and NiTi highly deformable structures manufactured through laser powder bed fusion

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2026年3月20日

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  • Simone Bonati,
  • Nicola Bennato,
  • Adelaide Nespoli

摘要

This work introduces a thin-walled, modular flexible structure, the Highly Deformable Structure (HDS), specifically engineered to exhibit bending-dominated behavior and a deployable mechanism, enabling large deformations, high energy absorption, and superior flexibility. HDS specimens were fabricated through Laser Powder Bed Fusion (LPBF) process using three different materials: SS316L, AlSi10Mg and NiTi. The study combined morphological analyses and mechanical characterizations to provide a comprehensive assessment of their performance. The results demonstrate that the HDS geometry accommodates significant deformations without structural failure, confirming the robustness of the design. Dynamic analyses conducted at 2 Hz showed that, among the tested alloys, NiTi exhibited the highest damping capacity, with a tanδ of 0.035 at 1% deformation amplitude, at a mean force of 20 N and at 5 °C (corresponding to austenite start temperature As). In comparison, SS316L and AlSi10Mg HDS cells also showed excellent dynamic response within the plastic regime at strain below 0.5%. Furthermore, the NiTi-based HDS benefits from shape memory effect, recovering over 50% of the applied deformation, which makes it particularly suitable for impact-resistance applications. These findings highlight the potential of LPBF in developing next-generation metallic components with tunable deformability, enabling advances in load bearing, damping and energy absorbing systems.