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A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: closed (20 October 2023) | Viewed by 11176

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Dr. Xinwei Li

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College of Design and Engineering, National University of Singapore, 9 Engineering Drive 1, Singapore 117575, Singapore
Interests: microlattices; metamaterials; finite element modeling; topological design; machine learning; 3D printing; mechanical properties; structural-property relationships
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Dear Colleagues,

The advent of three-dimensional (3D) printing brings about the possibilities of designing functional materials based on their structures as opposed to their chemistry. Specifically, these materials are designed with the introduction of architectured pores, and they are also porous and periodic in nature. A new class of material, known as lattice structure, manifests from this. Various types of lattice structures, with features based on struts, shells, plates, and their hybrids, exist. Owing to their unique porous and cellular structure, they often display properties not commonly found in traditional bulk materials, such as being lightweight, with an usually low/high specific stiffness and strength, deforming with a stress plateau region, having a high specific surface area, with unique flow properties, and with meta-mechanical behaviors. For instance, they are most commonly used as structural and protective materials for them to be lightweight and with an energy-absorbing behavior derived from the stress plateau. For their reduced stiffness and strength, they are also used as artificial bone implants whereby their bone-matching mechanical properties help to overcome the problem of stress shielding. Their high specific surface area, which allows maximized mass interactions, in turn allows them to be used as electrochemical electrodes, membranes, and filters. For their designable fluid flow properties, they are also attracting attention as acoustic metamaterials. With virtually unlimited possibilities in structural design, and (3D printable) material selections/combinations, it is apparent that there is a lot more that we can discover when it comes to the potentials of functional lattice structures.

This Special Issue welcomes all articles related to the 3D printing of lattice structures, including to but not limited to their design, materials processing, applications and performance, and mechanisms. This Special Issue also aims to help to advance the scientific and technical understandings of 3D-printed functional lattice structures.

Dr. Xinwei Li
Guest Editor

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Keywords

3D printing
lattice structure
metamaterial
finite element modeling
topological design
mechanical properties
lightweight
energy absorption
electrodes
acoustic
implant

Published Papers (7 papers)

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Research

24 pages, 65934 KiB

Open AccessArticle

A Novel 3D-Printed Negative-Stiffness Lattice Structure with Internal Resonance Characteristics and Tunable Bandgap Properties

by Jiayang Liu and Shu Li

Materials 2023, 16(24), 7669; https://doi.org/10.3390/ma16247669 - 15 Dec 2023

Viewed by 726

Abstract

The bandgap tuning potential offered by negative-stiffness lattice structures, characterized by their unique mechanical properties, represents a promising and burgeoning field. The potential of large deformations in lattice structures to transition between stable configurations is explored in this study. This transformation offers a novel method for modifying the frequency range of elastic wave attenuation, simultaneously absorbing energy and effectively generating diverse bandgap ranges. In this paper, an enhanced lattice structure is introduced, building upon the foundation of the normal negative-stiffness lattice structures. The research examined the behavior of the suggested negative-stiffness lattice structures when subjected to uniaxial compression. This included analyzing the dispersion spectra and bandgaps across different states of deformation. It also delved into the effects of geometric parameter changes on bandgap properties. Furthermore, the findings highlight that the normal negative-stiffness lattice structure demonstrates restricted capabilities in attenuating vibrations. In contrast, notable performance improvements are displayed by the improved negative-stiffness lattice structure, featuring distinct energy band structures and variable bandgap ranges in response to differing deformation states. This highlights the feasibility of bandgap tuning through the deformation of negatively stiffened structures. Finally, the overall metamaterial structure is simulated using a unit cell finite element dynamic model, and its vibration transmission properties and frequency response patterns are analyzed. A fresh perspective on the research and design of negative-stiffness lattice structures, particularly focusing on their bandgap tuning capabilities, is offered in this study. Full article

(This article belongs to the Special Issue 3D Printed Functional Lattice Structures)

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17 pages, 5509 KiB

Open AccessArticle

The Laser Selective Sintering Controlled Forming of Flexible TPMS Structures

by Chenhao Xue, Nan Li, Shenggui Chen, Jiahua Liang and Wurikaixi Aiyiti

Materials 2023, 16(24), 7565; https://doi.org/10.3390/ma16247565 - 08 Dec 2023

Viewed by 881

Abstract

Sports equipment crafted from flexible mechanical metamaterials offers advantages due to its lightweight, comfort, and energy absorption, enhancing athletes’ well-being and optimizing their competitive performance. The utilization of metamaterials in sports gear like insoles, protective equipment, and helmets has garnered increasing attention. In comparison to traditional truss and honeycomb metamaterials, the triply periodic minimal surface lattice structure stands out due to its parametric design capabilities, enabling controllable performance. Furthermore, the use of flexible materials empowers this structure to endure significant deformation while boasting a higher energy absorption capacity. Consequently, this study first introduces a parametric method based on the modeling equation of the triply periodic minimal surface structure and homogenization theory simulation. Experimental results demonstrate the efficacy of this method in designing triply periodic minimal surface lattice structures with a controllable and adjustable elastic modulus. Subsequently, the uniform flexible triply periodic minimal surface lattice structure is fabricated using laser selective sintering thermoplastic polyurethane technology. Compression tests and finite element simulations analyze the hyperelastic response characteristics, including the element type, deformation behavior, elastic modulus, and energy absorption performance, elucidating the stress–strain curve of the flexible lattice structure. Upon analyzing the compressive mechanical properties of the uniform flexible triply periodic minimal surface structure, it is evident that the structure’s geometric shape and volume fraction predominantly influence its mechanical properties. Consequently, we delve into the advantages of gradient and hybrid lattice structure designs concerning their elasticity, energy absorption, and shock absorption. Full article

(This article belongs to the Special Issue 3D Printed Functional Lattice Structures)

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18 pages, 8799 KiB

Open AccessArticle

Design and Manufacturing of a Novel Trabecular Tibial Implant

by Yongdi Zhang, Baoyu Sun, Lisong Zhao and Guang Yang

Materials 2023, 16(13), 4720; https://doi.org/10.3390/ma16134720 - 29 Jun 2023

Cited by 2 | Viewed by 1010

Abstract

The elastic modulus of traditional solid titanium alloy tibial implants is much higher than that of human bones, which can cause stress shielding. Designing them as a porous structure to form a bone-like trabecular structure effectively reduces stress shielding. However, the actual loading conditions of bones in different parts of the human body have not been considered for some trabecular structures, and their mechanical properties have not been considered concerning the personalized differences of other patients. Therefore, based on the elastic modulus of the tibial stem obtained from Quantitative Computed Tomography (QCT) imaging between 3.031 and10.528 GPa, and the load-bearing state of the tibia at the knee joint, a porous structure was designed under compressive and shear loading modes using topology optimization. Through comprehensive analysis of the mechanical and permeability properties of the porous structure, the results show that the Topology Optimization–Shear-2 (TO-S2) structure has the best compressive, shear mechanical properties and permeability and is suitable as a trabecular structure for tibial implants. The Gibson–Ashby model was established to control the mechanical properties of porous titanium alloy. A gradient filling of porous titanium alloy with a strut diameter of 0.106–0.202 mm was performed on the tibial stem based on the elastic modulus range, achieving precise matching of the mechanical properties of tibial implants and closer to the natural structure than uniformly distributed porous structures in human bones. Finally, the new tibial implant was printed by selective laser melting (SLM), and the molding effect was excellent. Full article

(This article belongs to the Special Issue 3D Printed Functional Lattice Structures)

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21 pages, 10918 KiB

Open AccessArticle

Superior Mechanical Properties of Invar36 Alloy Lattices Structures Manufactured by Laser Powder Bed Fusion

by Gongming He, Xiaoqiang Peng, Haotian Zhou, Guoliang Huang, Yanjun Xie, Yong He, Han Liu and Ke Huang

Materials 2023, 16(12), 4433; https://doi.org/10.3390/ma16124433 - 16 Jun 2023

Cited by 6 | Viewed by 1353

Abstract

Invar36 alloy is a low expansion alloy, and the triply periodic minimal surfaces (TPMS) structures have excellent lightweight, high energy absorption capacity and superior thermal and acoustic insulation properties. It is, however, difficult to manufacture by traditional processing methods. Laser powder bed fusion (LPBF) as a metal additive manufacturing technology, is extremely advantageous for forming complex lattice structures. In this study, five different TPMS cell structures, Gyroid (G), Diamond (D), Schwarz-P (P), Lidinoid (L), and Neovius (N) with Invar36 alloy as the material, were prepared using the LPBF process. The deformation behavior, mechanical properties, and energy absorption efficiency of these structures under different load directions were studied, and the effects and mechanisms of structure design, wall thickness, and load direction were further investigated. The results show that except for the P cell structure, which collapsed layer by layer, the other four TPMS cell structures all exhibited uniform plastic collapse. The G and D cell structures had excellent mechanical properties, and the energy absorption efficiency could reach more than 80%. In addition, it was found that the wall thickness could adjust the apparent density, relative platform stress, relative stiffness, energy absorption, energy absorption efficiency, and deformation behavior of the structure. Printed TPMS cell structures have better mechanical properties in the horizontal direction due to intrinsic printing process and structural design. Full article

(This article belongs to the Special Issue 3D Printed Functional Lattice Structures)

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10 pages, 3432 KiB

Open AccessArticle

Damping and Mechanical Properties of Epoxy/316L Metallic Lattice Composites

by Yanpeng Wei, Huaiqian Li, Hao Yang, Yingchun Ma, Jingchang Cheng, Peng Gao, Jian Shi, Bo Yu and Feng Lin

Materials 2023, 16(1), 130; https://doi.org/10.3390/ma16010130 - 23 Dec 2022

Cited by 3 | Viewed by 2932

Abstract

The lattice structure was prepared by selective laser melting of 316L metal powder, and the epoxy was naturally infiltrated into the pores of the 316L metallic lattice structure. The epoxy/316L metallic lattice composites with integrated structure and function were prepared. Scanning electron microscopy was used to observe the microstructure of the epoxy/316L metallic lattice composites. The damping performance of the epoxy/316L metallic lattice composites were studied by modal measurement method. At the same time, the engineering stress–strain curve was obtained by a quasi-static compression experiment on a universal testing machine. The results show that the interface of epoxy and 316L metallic lattice is well bonded, and there are a few bubbles in the epoxy. The epoxy/316L metallic lattice composites have high damping characteristics with damping ratio over 10%. The energy absorption of epoxy/316L metallic lattice composites is as high as 68.32 MJ/m³, showing high energy absorption characteristics. Full article

(This article belongs to the Special Issue 3D Printed Functional Lattice Structures)

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13 pages, 6253 KiB

Open AccessArticle

Thermal Insulation and Compressive Performances of 3D Printing Flexible Load-Bearing and Thermal Insulation Integrated Lattice

by Xin Wang, Ang Li, Xuefeng Liu and Xiangrui Wan

Materials 2022, 15(23), 8625; https://doi.org/10.3390/ma15238625 - 02 Dec 2022

Cited by 1 | Viewed by 1369

Abstract

Structurally and functionally integrated materials usually face the problem of serious functional degradation after large deformation or fracture, such as load-bearing and thermal insulation integrated lattice. In this work, the lattice with a big width-thickness ratio, which empowered the flexibility of the lattice by reducing the rod deformation during compression, was proposed. The structure of the lattice almost kept integrality after large deformation or fracture, and the decay of thermal insulation performance was less. Compared with the conventional lattice, the big width-thickness ratio lattice obtained favorable thermal insulation performance. On this basis, two kinds of flexible load-bearing and thermal insulation integrated hourglass lattices with big width-thickness ratios (BWR lattice) were prepared by SLM, and the thermal insulation and compressive performances were measured. The thermal insulation efficiency could reach 83% at 700 °C. The lattice would recover after large deformation or fracture, and the thermal insulation efficiency of the fracture lattice was 75%. This work provides a new way of designing load-bearing and thermal insulation integrated lattice and achieves the functionality preservation of load-bearing and thermal insulation integrated lattice after large deformations and fractures. Full article

(This article belongs to the Special Issue 3D Printed Functional Lattice Structures)

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18 pages, 12006 KiB

Open AccessArticle

Distortion Prediction in Inconel-718 Part Fabricated through LPBF by Using Homogenized Support Properties from Experiments and Numerical Simulation

by Varun Ananda, Gurunathan Saravana Kumar, Rengaswamy Jayaganthan and Balamurugan Srinivasan

Materials 2022, 15(17), 5909; https://doi.org/10.3390/ma15175909 - 26 Aug 2022

Cited by 1 | Viewed by 1573

Abstract

The Laser Powder-Bed Fusion (LPBF) process produces complex part geometry by selectively sintering powder metal layer upon layer. During the LPBF process, parts experience the challenge of residual stress, distortions, and print failures. Lattice-based structures are used to support overhang parts and reduce distortion; this lattice support has complex geometry and demands high computational effort to predict distortion using simulation. This study proposes a computational efforts reduction strategy by replacing complex lattice support geometry with homogenization using experimentally determined mechanical properties. Many homogenization models have been established to relate the lattice topology and material properties to the observed mechanical properties, like the Gibson–Ashby model. However, these predicted properties vary from as printed lattice geometry. In this work, the power-law relationship of mechanical properties for additively manufactured Inconel 718 part is obtained using tensile tests of various lattice support topologies and the model is used for homogenization in simulation. The model’s accuracy in predicting distortion in printed parts is demonstrated using simulation results for a cantilever model. Simulation studies show that computational speed is significantly increased (6–7 times) using the homogenization technique without compromising the accuracy of distortion prediction. Full article

(This article belongs to the Special Issue 3D Printed Functional Lattice Structures)

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