Evaluations of cellular lattice structures manufactured using selective laser melting

Metallic additive manufacturing techniques, in particular the selective laser melting (SLM) process, are capable of fabricating strong, lightweight and complex metallic lattice structures. However, they still face certain process limitations such as geometrical constraints and in some cases the need for support structures. This study evaluates the manufacturability and performance of SLM produced periodic cellular lattice structures, which are designed by repeating a unit cell type called gyroid consisting of circular struts and a spherical core. The effect of unit cell size on the manufacturability, density and compression properties of the manufactured cellular lattice structures were investigated. Micro-computer tomography (CT) scan results reveal that the gyroid cellular lattice structures with various unit cell sizes ranging from 2 to 8 mm can be manufactured free of defects by the SLM process without the need of additional support structures. The Scanning Electron Microscope (SEM) micrographs show that the lattice structures made by SLM have a good geometric agreement with the original computer-aided design (CAD) models, but many partially melted metal particles are bonded to strut surfaces. The struts within the gyroid cellular lattice structures with smaller unit cell sizes have higher densities due to their shorter scan vector lengths in the SLM process. The yield strength and Young's modulus of the Gyroid cellular lattice structures increase with the decrease in the unit cell size due to the denser struts of the lattice structures with smaller unit cell sizes.

► Cellular lattice structures are generated by a novel unit cell type called “Schoen Gyroid”.
► The lattice structures with a wide unit cell size range were manufactured by SLM.
► Struts within the lattice structures with smaller unit cell sizes have higher densities.
► The yield strengths and Young's moduli both decrease with the increase in unit cell size.