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Updated: Aug 1, 2025

Indirect Fabrication of Lattice Metals with Thin Sections Using Centrifugal Casting
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Mechanical Performance of Three-Dimensional Printed Lattice Structures: Assembled Versus Direct Print.

Adeeb Alam1, Keith Berube2, Masoud Rais-Rohani1

  • 1Department of Mechanical Engineering, The University of Maine, Orono, Maine, USA.

3D Printing and Additive Manufacturing
|May 1, 2023
PubMed
Summary

A novel assembly method for lattice structures improves interlayer adhesion and mechanical properties by minimizing contour plurality in additive manufacturing. This approach enhances structural integrity compared to traditional direct printing.

Keywords:
3D printed assembled structurecontour pluralitylattice structuremechanical performance of 3D printed part

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Area of Science:

  • Materials Science
  • Mechanical Engineering
  • Additive Manufacturing

Background:

  • Inclined struts in lattice structures create disjoint contours during additive manufacturing (AM), leading to contour plurality.
  • Contour plurality reduces interlayer contact, negatively impacting adhesion, structural integrity, and mechanical properties of printed lattice structures.

Purpose of the Study:

  • To investigate a new interlocking and assembly-based approach for building lattice structures.
  • To enhance layer continuity and minimize contour plurality, thereby improving mechanical performance.
  • To compare the compressive performance of assembled lattice structures with traditionally direct-printed ones.

Main Methods:

  • Examined two lattice configurations: cubic and octet.
  • Developed an interlocking and assembly-based building approach to increase layer continuity.
  • Compared the compressive performance of assembled lattice structures against direct-printed counterparts.

Main Results:

  • Assembled lattice structures demonstrated generally superior mechanical performance (peak stress, specific energy absorption) compared to direct-printed structures.
  • Empirical constants in the Ashby-Gibson power law were higher for both methods but more compliant for assembled octet structures.
  • Assembled octet lattice structures showed greater resilience to manufacturing imperfections.

Conclusions:

  • The interlocking and assembly-based approach effectively mitigates contour plurality issues in AM lattice structures.
  • This method offers a viable strategy for improving the mechanical properties and structural integrity of 3D-printed lattices.
  • Octet assembled structures present a promising direction for robust and high-performance lattice designs.