SIM-AM 2025

Single vector exposed thin-walled lattice structure in LPBF: Manufacturing, Design, FEM simulation and Testing

  • Abbatiello, Vincenzo (EOS GmbH - TU Darmstadt)
  • Mittlested, Christian (TU Darmstadt)

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The increasing demand for lightweight structures with enhanced performance is constantly pushing the boundaries of manufacturing technologies. Laser Powder Bed Fusion (LPBF) offers significant advantages in terms of design freedom, reduced lead times, and the ability to overcome limitations of conventional manufacturing, making it a crucial technology for realizing such advanced components. While extensive research in LPBF has explored Generative Design approaches, particularly topology optimization and periodic/stochastic trabecular lattice structures, investigations into the design, manufacturing, and characterization of very thin-walled lattice structures remain comparatively limited, also for other Additive Manufacturing techniques. This work aims to define and validate a comprehensive workflow encompassing the design, manufacturing, mechanical characterization, and potential scaling of thin-walled lattice structures for diverse potential applications, including lightweight and stiff reinforced panels for aerospace, energy-absorbing shock absorbers for impactors, and high-surface-area heat exchangers for various industries. A key innovation of this research lies in the manufacturing technique: each wall is fabricated by exposing the metal powder with a single-line laser vector. This unique approach enables the creation of exceptionally thin and detailed walls, allowing for precise control over wall thickness independent of the initial design. This single-vector manufacturing approach offers the potential for a faster and more stable fabrication process compared to standard LPBF exposure strategies. Utilizing this method, compression specimens with multiple cells arrayed in the x, y, and z directions have been manufactured and experimentally tested using a compression testing machine. Furthermore, explicit compression analysis has been conducted to correlate the experimental findings with simulated behaviour.