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Updated: Aug 6, 2026
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Fused Filament Fabrication (FFF) of Metal-Ceramic Components
Published on: January 11, 2019
Process-structure relationships in LPBF-fabricated lattice interlocks for injection molded metal-polymer joining
Mijin Kim1, Min-Kyo Jung1, Siwon Yu2
1Department of 3D Printing, Korea Institute of Machinery & Materials, Daejeon, 34103, Republic of Korea.
Scientific Reports
|July 17, 2026
Summary
This study introduces a novel laser powder bed fusion (LPBF) method for direct metal-polymer joining using lattice structures. The research highlights the critical interplay between lattice design and injection molding conditions for optimal hybrid structure performance.
Area of Science:
- Materials Science
- Manufacturing Engineering
- Additive Manufacturing
Background:
- Conventional metal-polymer joining methods lack reproducibility and design flexibility.
- Lightweight, high-performance hybrid structures are in demand for advanced applications.
Purpose of the Study:
- To develop and evaluate a process-informed structural interlocking strategy for direct metal-polymer joining.
- To investigate the influence of injection molding conditions on the performance of laser powder bed fusion (LPBF)-fabricated lattice structures.
Main Methods:
- Fabrication of AlSi10Mg lattice structures using LPBF.
- Experimental assessment of mechanical responses via injection molding and tensile testing.
- Analysis of injection molding simulations to determine pressure distribution and structural deformation.
Main Results:
- All lattice configurations achieved stable metal-polymer bonding.
- Tensile strength decreased with increasing lattice complexity, up to 23.6%.
- Lattice density impacts flow behavior and structural response, creating a trade-off between injection pressure and deformation.
Conclusions:
- Lattice performance in metal-polymer joining depends on both structural design and processing conditions.
- A process-structure integrated evaluation framework is crucial for LPBF-based lattice interlocking in injection molding.
- The proposed strategy enhances design flexibility and reproducibility for hybrid structures.
