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3D metal lattice structure manufacturing with continuous rods.

Bashir Khoda1, A M M Nazmul Ahsan2, Abu N Shovon3

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Researchers developed a novel method for fabricating metal lattice structures using continuous rods. This technique effectively joins nodes via a dipping process, enabling strong, lightweight 3D metal lattices with tunable mechanical properties.

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Area of Science:

  • Materials Science
  • Mechanical Engineering
  • Additive Manufacturing

Background:

  • Fabricating continuous metal lattice structures with joined nodes is challenging.
  • Existing methods struggle with node joining in complex lattice designs.

Purpose of the Study:

  • To demonstrate a new method for fabricating metal lattice structures with continuous rods.
  • To investigate node joining techniques for loose lattice structures using a dipping process.
  • To characterize the mechanical properties of the fabricated 3D metal lattice structures.

Main Methods:

  • Developed a dipping process for delivering joining agents (epoxy for polymer-metal, inorganic particles for metal-metal).
  • Designed Liquid Carrier Systems (LCS) considering rheological behavior for efficient particle transfer.
  • Utilized transient liquid phase bonding (TLP) for joining lattice nodes.
  • Constructed and mechanically tested 3D metal lattice structures with varying cell sizes and relative densities.

Main Results:

  • Achieved successful node joining in loose lattice structures using the dipping process.
  • 40% solid loading in LCS proved effective for particle transfer and node joining via TLP.
  • Fabricated 3D metal lattice structures exhibited comparable strength at low relative densities (<10%).
  • Strength and elastic modulus decreased with increasing cell size, aligning with established principles.

Conclusions:

  • The dipping process offers a viable solution for joining nodes in continuous metal lattice structures.
  • The developed LCS and TLP method enable the fabrication of strong, lightweight 3D metal lattices.
  • The findings contribute to advancements in additive manufacturing and materials science for structural applications.