A Qualitative Comparison of Dimensional Deviation of Laser Powder Bed Fusion Processed Multi Morphology Lattice Structures Based on Thermomechanical Simulations

Abstract

Multi morphology lattices are composite lattice structures formed by different types of lattice structures in different configurations based on engineering application needs. These types of lattices can be manufactured with additive manufacturing modalities, specifically laser powder bed fusion process. However, due to the high cost and time spent on manufacturing these components, it is necessary to predict the properties of manufactured parts before build with numerical methods. This study focused on prediction of dimensional deviation of laser powder bed fusion produced multi morphology lattice structures composed of Schoen Gyroid, Schwarz Diamond, Schwarz Primitive, Schoen FRD and Neovius topologies via thermomechanical simulations qualitatively. Since the comparisons were made based on numerical study results, only qualitative assessments were performed. Lattices were generated by using a novel, in-house developed tool. Among multi morphology lattices investigated in the present study, Schoen FRD topology at the center and Schwarz Primitive topology at the outer region showed the lowest deviations and Schoen FRD topology at the center and Schwarz Diamond topology at the outer region showed the highest deviations. It was also shown that adding Schoen FRD or Schwarz Primitive topologies at the outer region reduces the max. deviations, and Schoen Gyroid or Schwarz Diamond topologies increases the max. deviations.