Cellular Structures Analysis Under Compression Test

Cellular structures, formed by periodic two- or three-dimensional cells, offer weight reduction without compromising mechanical performance and are commonly fabricated via additive manufacturing. This study investigates the compressive behaviour of three polymer lattice structures-gyroid, diamond, and octet truss-fabricated by fused filament fabrication (FFF). A Box-Behnken experimental design was used to systematically evaluate the influence of three key parameters: cell size, strut/wall thickness, and layer thickness. A total of 225 samples were produced using PLA and subjected to compression testing in accordance with ASTM D1621. Linear regression and response surface methodology were employed to determine the statistical significance and impact of each factor. The results indicate that cell size has the strongest influence on both maximum force and displacement, followed by strut/wall thickness and layer thickness. Among the configurations, gyroid structures had the highest strength-to-density ratio, while diamond structures had the highest deformation capacity. These findings provide design insights for optimising lattice structures in lightweight applications and highlight the importance of carefully balancing geometric and printing parameters in FFF-based polymer components.