Novel “load adaptive algorithm based” procedure for 3D printing of lattice-based components showing parametric curved micro-beams

This work deals with the development, the application and the experimental validation of a procedure based on an algorithm, running in a finite element environment replacing the continuous mass of convex solids with a cancellous bone-inspired lattice structure showing curved beams oriented on the basis of the external forces, sharing with it border and boundary conditions. For the validation of the new lattice structure a cubic representative volume element, showing curved micro-beams, was chosen, implementing periodic boundary conditions. At the end, the algorithm created a .stl file to be printed by a 3D printer using an appropriate polymer. The numerical results were compared with experimental results obtained by compression tests. The experimental/numerical correlation confirmed the validity of the FEM “beam element - based” lattice structure that could be applied to different solid shapes.