Imperfections and computational modeling of lattice structures developed through powder bed fusion – A short review

Abstract

Additive manufactured lattice structures (AMLS) are widely preferred for a variety of engineering applications because they offer superior performance over traditional structures. AMLS are not error-free, and therefore estimating their mechanical properties with decent computational accuracy remains a challenge that can be eliminated by including the errors in the CAD model. A typical numerical analysis begins with the development of an idealized computational model, neglecting manufacturing errors such as strut surface imperfections, strut waviness, and variances in strut diameter, leading to oversimplification. Likewise, the inclusion of defects in the computational model creates complex finite element meshes, increasing the level of complexity of the analysis and limiting the number of unit cells used to develop the model, emphasizing the need for a simplified model to include the induced defects will the manufacturing process into the lattice structures. This review article presents different strategies adopted to develop computational models with a range of manufacturing errors for finite element analysis, and the results are compared to an idealized model to estimate the deformation properties with a higher degree of accuracy and correlations to experiments.