Design of Additive Manufactured Hybrid Lattice Structures for Enhanced Mechanical Performance

Abstract

By enabling the manufacture of sophisticated lattice structures with tailored mechanical qualities, additive manufacturing has changed the fabrication of complex geometries. This work offers a hybrid lattice design meant to enhance mechanical performance and energy absorption by combining bending-dominated face-centered cubic (FCC) cells with stretch-dominated Iso Truss cells. Systematically created were nine separate hybrid lattice configurations made up of linked face-centered cubic (IFCC) and hybrid designs marked HS1 through HS5. Selected for its biodegradability and beneficial mechanical qualities, polylactic acid (PLA) was employed to construct the structures utilizing the fused deposition modeling (FDM) technique. Essential for correct performance assessment, the manufacturing technique was honed to ensure accuracy and structural integrity. Mechanical behavior and energy absorption characteristics of the suggested lattice architectures were evaluated using finite element models. Under quasi-static compression loads, the simulations produced knowledge on stress distribution, deformation patterns, and expected failure mechanisms. Quasi-static compression tests were done to confirm the modeling findings and explore the real deformation processes. The experimental setting followed defined testing techniques to assure the reliability and repeatability of the findings. The results suggested that the unique hybrid lattice structure (IFCC) displayed increased mechanical performance compared to homogeneous FCC and ISO truss structures, notably in load-bearing capacity, stiffness, and specific energy absorption (SEA). The inclusion of a layered staking hybrid lattice architecture boosted mechanical performance and transformed the deformation process to a more controlled layer-by-layer failure mode. The IFCC hybrid lattice acquired a specific energy absorption (SEA) of 3.93 kJ/kg. Among the layered hybrid topologies, HS4 displayed the greatest SEA of 5.96 kJ/kg, representing increases of 332% and 555% compared to homogeneous FCC and ISO truss structures, respectively. The results emphasize the potential of hybrid lattice structures to produce customized mechanical characteristics in energy-absorbing applications, aiding future improvements in lightweight, high-performance materials. shown that some hybrid arrangements, notably HS4 and HS5, exhibited increased energy absorption and structural integrity compared to alternative designs. The arrangements displayed a synergistic impact by successfully combining the positive features of both bending-dominated and stretch-dominated cells. In contrast, designs like HS3 and IFCC demonstrated modest energy dissipation, typified by varied deformation behaviors that indicated a poor balance between stiffness and energy absorption. The study underlines the need of combining varied lattice geometry to get specific mechanical characteristics. Utilizing the geometric and material flexibility of additive printing allows the construction of lattice structures suited for specific uses. This research gives substantial insights for the production of lightweight, high-performance materials useful in energy-absorbing situations, such as protective equipment, automobile components, and aircraft frameworks.