Laser additive manufacturing of metallic lattice structures: material-structure-property concept, and future perspective

Metallic lattice structures have emerged as revolutionary lightweight materials with exceptional specific strength and multifunctional capabilities, particularly in aerospace applications. This review comprehensively examines the state of the art in laser additive manufacturing (LAM) of metallic lattice structures, focusing on selective laser melting (SLM) and electron beam melting (EBM). We critically analyze recent advances in materials development, including nickel-based superalloys (GH4169/IN718, K465), titanium alloys (Ti-6Al-4V), and functionally graded composites. The review addresses key design considerations, including unit cell topology optimization, node reinforcement strategies, and gradient structures. We examine mechanical properties under various loading conditions, thermal management capabilities, and failure mechanisms through both experimental and numerical perspectives. Advanced detection methods, including micro-CT imaging and AI-based defect identification, are evaluated for quality assurance. Critical challenges, including surface roughness control, residual stress management, and size limitations, are discussed alongside emerging opportunities in machine-learning-assisted design and multi-material systems. This review provides essential insights for researchers and engineers seeking to advance lattice-structured applications in next-generation aerospace systems.