Evaluating Tetrahedral Latticed Cubes Optimized for Additive Manufacturing Through Finite Element Analysis and Geometric Scanning Validation

Additive manufacturing (AM) continues to grow in engineering fields due to its capability to manufacture complex geometries. AM processes such as laser powder bed fusion (LPBF), in particular, have gained increasing relevance within the aerospace industry due to their effectiveness in developing complex geometries. One of the most critical objectives in the aerospace industry is to create high strength-to-weight ratio components. Thus, lattice structures are an ideal candidate to achieve this goal due to their low weight and high specific strength characteristics. However, metal AM is expensive and time-consuming, and there has been limited work in predicting the build results of complex lattice structures. If a complex part has not been optimized or designed for AM, there is the potential for build failure, or it may not be worth printing. Finite element analysis (FEA) of the AM process has proven to be an efficient resource for avoiding build failure and saving manufacturers’ time and money. This study examines the printability of a novel type of tetrahedral lattice based on the bubble-mesh method. In this work, FEA AM simulations are performed to examine how adjusting the parameters of the lattice generation method can lead to latticed cube designs that are optimal for LPBF printability. The results showed the lattice generation method could design lattices with ideal overhang angles (>45°) that are less likely to fail during an AM build due to lower deformations. The AM-optimized lattices were then printed and scanned to examine AM process deformations and validate the AM simulations. It was found that the latticed cube with a larger overhang angle had lower roughness and deformations, which agreed with the deformations findings from the AM simulations.