Advanced lightweight 316L stainless steel cellular lattice structures fabricated via selective laser melting

• A unique cell type called gyroid is designed to construct lattice structures.
• Curved cell surface as a self-supported feature avoids support structures.
• Lattice structures with a wide volume fraction range were made.
• Lattice structures were made at different orientations.
• Strength and modulus increase with the increase in the volume fraction.

This paper investigates the manufacturability and performance of advanced and lightweight stainless steel cellular lattice structures fabricated via selective laser melting (SLM). A unique cell type called gyroid is designed to construct periodic lattice structures and utilise its curved cell surface as a self-supported feature which avoids the building of support structures and reduces material waste and production time. The gyroid cellular lattice structures with a wide range of volume fraction were made at different orientations, showing it can reduce the constraints in design for the SLM and provide flexibility in selecting optimal manufacturing parameters. The lattice structures with different volume fraction were well manufactured by the SLM process to exhibit a good geometric agreement with the original CAD models. The strut of the SLM-manufactured lattice structures represents a rough surface and its size is slightly higher than the designed value. When the lattice structure was positioned with half of its struts at an angle of 0° with respect to the building plane, which is considered as the worst building orientation for SLM, it was manufactured with well-defined struts and no defects or broken cells. The compression strength and modulus of the lattice structures increase with the increase in the volume fraction, and two equations based on Gibson–Ashby model have been established to predict their compression properties.