
Design and Mechanical Properties of Hybrid Lattice Structures for Additive Manufacturing
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Additive manufacturing enables the fabrication of lightweight high-strength lattice structures. Depending on the desired mechanical properties and application, lattice structures, also considered as architectured materials, can be designed to specific forms to meet specific requirements. With lattice structure designs ranging from strut-based to triply periodic minimal surface (TPMS) lattices, variations in density, joint shapes, and types, the possible configurations and design choices are virtually limitless. The properties of each structure depend on the lattice structure pattern, relative density and base material properties. However, most previous lattice structure designs have mainly focused on single-type and uniform lattice structure configurations. This research aims to explore new lattice structure designs by combining different strut-based and surface-based lattice structures to achieve enhanced mechanical performance. In this work, these new lattice structure designs, defined as hybrid lattice structures, are introduced to explore the potential of combining different design configurations to achieve enhanced mechanical properties. Hybrid structures are created by combining strut-strut, surface-surface, and strut-surface lattices through layering, embedding, or alternating arrangements. The methodology involves designing hybrid lattice structures and performing finite element analysis (FEA) to evaluate their mechanical behaviour. The results show that combining different lattice structure configurations can improve the lattice structure mechanical properties compared to conventional uniform lattice structures. In conclusion, hybrid lattice structures offer a promising approach to enhancing the mechanical properties of additively manufactured parts and achieving multifunctional performance. The choice of hybrid design depends on the specific mechanical and functional requirements of the intended application. This research contributes to the broader application of lattice structures in the automotive, biomedical and aerospace industries.