Design of lattice structure for additive manufacturing

Additive Manufacturing (AM) technology provides new opportunities to automatically and flexibly fabricate parts with complicated shapes and architectures that could not be produced by conventional manufacturing processes, thus enabling unprecedented design flexibilities and application opportunities. The lattice structure possesses many superior properties to solid material and conventional structures. It is able to integrate more than one function into a physical part, which makes it attractive to a wide range of applications. With AM technology the lattice structure can be fabricated by adding material layer-by-layer directly from a Computer-Aided Design (CAD) model, rather than the conventional processes with complicated procedures. AM lattice structures have been intensively studied for more than ten years with significant progress having been made. This paper reviews and discusses AM processes, design methods and considerations, mechanical behavior, and applications for lattice structures enabled by this emerging technology.

[1]  Gregory E. Hilmas,et al.  Freeze-form extrusion fabrication of ceramic parts , 2006 .

[2]  A. Clausen Topology Optimization for Additive Manufacturing , 2016 .

[3]  M. Leu,et al.  Freeform Extrusion Fabrication of Titanium Fiber Reinforced Bioactive Glass Scaffolds , 2015 .

[4]  Claus Emmelmann,et al.  Selective Laser Melting of Honeycombs with Negative Poisson's Ratio , 2009 .

[5]  J. Kruth,et al.  Effects of build orientation and heat treatment on the microstructure and mechanical properties of selective laser melted Ti6Al4V lattice structures , 2015 .

[6]  Ming-Chuan Leu,et al.  Additive manufacturing: technology, applications and research needs , 2013, Frontiers of Mechanical Engineering.

[7]  K. Osakada,et al.  Flexible manufacturing of metallic products by selective laser melting of powder , 2006 .

[8]  Roderic S. Lakes,et al.  Design Considerations for Materials with Negative Poisson’s Ratios , 1993 .

[9]  Li Yang,et al.  Non-stochastic Ti–6Al–4V foam structures with negative Poisson's ratio , 2012 .

[10]  D. Yoo,et al.  Heterogeneous minimal surface porous scaffold design using the distance field and radial basis functions. , 2012, Medical engineering & physics.

[11]  Paul F. Jacobs,et al.  Rapid Prototyping & Manufacturing: Fundamentals of Stereolithography , 1992 .

[12]  R. Lakes,et al.  Indentability of Conventional and Negative Poisson's Ratio Foams , 1992 .

[13]  M. Wolcott Cellular solids: Structure and properties , 1990 .

[14]  H. Maier,et al.  In situ characterization of the deformation and failure behavior of non-stochastic porous structures processed by selective laser melting , 2011 .

[15]  David Rosen,et al.  Design of truss-like cellular structures using relative density mapping method , 2015 .

[16]  R. Lakes,et al.  Properties of a chiral honeycomb with a poisson's ratio of — 1 , 1997 .

[17]  M. Ashby The properties of foams and lattices , 2006, Philosophical Transactions of the Royal Society A: Mathematical, Physical and Engineering Sciences.

[18]  P. S. Grant,et al.  Manufacture of electrical and magnetic graded and anisotropic materials for novel manipulations of microwaves , 2015, Philosophical Transactions of the Royal Society A: Mathematical, Physical and Engineering Sciences.

[19]  M. Leu,et al.  Effect of Architecture and Porosity on Mechanical Properties of Borate Glass Scaffolds Made by Selective Laser Sintering , 2013 .

[20]  Paolo Colombo,et al.  Cellular Ceramics: Structure, Manufacturing, Properties and Applications , 2005 .

[21]  David W. Rosen,et al.  Conformal Lattice Structure Design and Fabrication , 2012 .

[22]  J. Beaman,et al.  Producing metal parts with selective laser sintering/hot isostatic pressing , 1998 .

[23]  Norman A. Fleck,et al.  Fabrication and structural performance of periodic cellular metal sandwich structures , 2003 .

[24]  David W. Rosen,et al.  Design of Truss-Like Cellular Structures Using Relative Density Mapping Method , 2014 .

[25]  S. Das,et al.  Producing metal parts with selective laser sintering/hot isostatic pressing , 1998 .

[26]  L Catherine Brinson,et al.  Mechanics considerations for microporous titanium as an orthopedic implant material. , 2004, Journal of biomedical materials research. Part A.

[27]  R. Lakes Foam Structures with a Negative Poisson's Ratio , 1987, Science.

[28]  Z. Eckel,et al.  Additive manufacturing of polymer-derived ceramics , 2016, Science.

[29]  Ming-Chuan Leu,et al.  In vitro assessment of laser sintered bioactive glass scaffolds with different pore geometries , 2015 .

[30]  Ryan B. Wicker,et al.  Fabricating Functional Ti-Alloy Biomedical Implants by Additive Manufacturing Using Electron Beam Melting , 2012 .

[31]  J. Grotowski,et al.  Prototypes for Bone Implant Scaffolds Designed via Topology Optimization and Manufactured by Solid Freeform Fabrication , 2010 .

[32]  J. B. Park,et al.  Negative Poisson's ratio polymeric and metallic foams , 1988 .

[33]  M. Ashby,et al.  FOAM TOPOLOGY BENDING VERSUS STRETCHING DOMINATED ARCHITECTURES , 2001 .