Computational and experimental investigation of lattice structures for tensile and compressive strength

Lattice structures are widely used in lightweight and energy absorbing applications. Their fabrication can be efficiently achieved using 3D printing techniques, enabling the production of components with reduced weight, high strength and enhanced energy absorption capabilities. This study investigates the mechanical performance of eight distinct lattice structures, including Grid, X, Cross, Star, Tesseract, Octet, Diamond and Honeycomb. It also explores their suitability for various engineering applications. A computational design model was developed using Rhinoceros 3D software integrated with the Intralattice plugin to generate unit cell based lattice geometries. The models were subsequently analyzed through finite element analysis (FEA) to evaluate equivalent stress, elastic strain and deformation for each structure under loading conditions. The computational results were further validated through experimental testing, in which 3D printed specimens were subjected to tensile and compressive tests using a universal testing machine. A comparative evaluation between simulation and experiment demonstrated a correlation, confirming the accuracy of the numerical models. Among the examined configurations, the Octet lattice exhibited the highest strength and load-bearing capacity, sustaining greater stresses with minimal deformation. The findings indicate that selecting an appropriate lattice structure depends on achieving an optimal balance between strength, stiffness and flexibility for the intended application.