ADDITIVE MANUFACTURING
LATTICE ANALYSIS T
Providing a reliable way to predict how new lattice designs can be fi ne-tuned to minimise structural defects
he design and construction of lattice materials relies on a delicate balance of structural factors. Researchers
at the University of Glasgow have been investigating the deformation mechanisms which cause 3D printed materials to fail under strain, culminating in a new design parameter called the ‘enhancement factor’. “The enhancement factor tool is
designed to bridge the gap between theoretical predictions and the actual performance of 3D printed lattice structures, helping engineers to optimise their designs,” says Professor Kumar Shanmugam, professor of composite materials and advanced manufacturing at the University of Glasgow. “The tool acts as a corrective factor that quantifi es the discrepancy between the ideal, defect-free lattice structure and the real, printed version, which may be aff ected by various factors such as printing defects and deposition strategy.”
STRUCTURAL BENEFITS According to Shanmugam, lattice designs off er many signifi cant benefi ts for industrial parts, primarily due to their unique structure. “One of the primary advantages of lattice materials is their ability to achieve high specifi c strength and stiff ness, making them ideal for structural applications,” he explains. “Additionally, their capacity to absorb energy makes them suitable for impact resistance and shock mitigation. This versatility enhances the performance of industrial components, particularly in applications requiring both strength and weight reduction.” Lightweighting is also an important
advantage of lattice designs. “The lightweight nature of lattice-designed components is a crucial advantage across industries like automotive, aerospace, robotics and biomedical fi elds, where reducing weight without compromising performance is essential,” he adds.
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www.engineerlive.com Analysis and testing of various 3D printed lattices
MEET THE CHALLENGE Additive manufacturing has emerged as an ideal production technology for developing new lattice designs, however challenges remain. Shanmugam’s team focused on overcoming these issues to produce structures with minimal defects, porosity and dimensional inconsistencies using 3D printing. “Engineers often rely on established
theoretical models to predict stiff ness, strength and energy absorption of lattice structures,” Shanmugam says. “However, these models are typically based on ideal conditions or on materials produced through traditional manufacturing methods. When it comes to additive manufacturing, the actual mechanical properties of the printed structures can diff er signifi cantly due to the unique challenges of the process.” The team’s enhancement factor
tool is designed to provide a practical means to connect theoretical mechanical properties to those of the actual 3D printed structures. “Engineers can assess the eff ective mechanical performance of their designs, accounting for the real-world imperfections introduced during the
printing process,” he continues. “This enables them to make more informed decisions about material selection, lattice architecture and process parameters, ultimately improving the performance and reliability of the fi nal product. Moreover, the enhancement factor tool serves as a diagnostic metric for the quality of the printing process.” By adhering to these guidelines,
engineers can design 3D printed lattices that are not only robust, but also optimised for advanced applications, he adds. “Our research holds signifi cant
potential for advancing component design and material development across various industrial applications. In automotive, fl awlessly produced lattice materials could revolutionise road safety, in aerospace, engineers could develop more fuel-eff icient aircraft, and customised implants made from 3D printed lattice materials could improve patient outcomes.”
Read the full research paper here:
https://onlinelibrary.wiley.com/ doi/full/10.1002/admt.202400457
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