Gyroid Lattice Research Articles

Microstructural and mechanical properties study of various lattice structures of SS316L-CNTs nano composites fabricated through additive manufacturing

Abstract In this work, various lattice structures, such as FCC (face-centered), BCC (body-centered), GD (Gyroid), and BGD (bare gyroid (without CNTs)) with four different porosities (60%, 70%, 80%, and 90%), were prepared through the SLM (selective laser melting) additive manufacturing process. Stainless Steel (SS) 316L alloy was utilized as the base material, while 0.2 wt.% functionalized CNTs (Carbon Nanotubes) were employed as reinforcement. The uniform dispersion of CNTs was analyzed using FESEM, TEM, and Raman spectroscopy. The results indicated that the plateau stress increases with the addition of CNTs, as well as with relative density, whereas energy absorption increases with the addition of CNTs. However, with increasing relative densities, energy absorption nature changes from increasing to decreasing. The results showed that among all lattice structures formed with CNTs addition, the Gyroid lattice exhibited the highest plateau stress, while the BCC lattice exhibited the lowest plateau stress.

Impact of lattice designs and production parameters on mechanical properties of AlSi10Mg in laser powder bed fusion

Abstract This study investigates the impact of lattice designs and production parameters on the mechanical properties of AlSi10Mg fabricated using Laser Powder Bed Fusion (L-PBF). The research explores the production and performance of gyroid, diamond, and lidinoid lattice structures under varying scanning speeds (600, 900, 1,200 mm s−1). Key findings indicate that scanning speed significantly influences mechanical properties and energy absorption capabilities. The gyroid lattice structure produced at 600 mm s−1 exhibited the highest compressive strength (76.51 MPa) and energy absorption (28.57 MJ m−3). SEM-EDS analysis revealed no substantial structural defects, while porosity and microstructural deformations were observed at higher scanning speeds. Finite element simulations demonstrated localized buckling and fissure formation in lattice structures under compressive loads. The study highlights the critical role of production parameters in optimizing the mechanical performance of L-PBF-manufactured AlSi10Mg, offering insights into achieving cost and time efficiencies in additive manufacturing processes. This comprehensive analysis contributes to advancing the application of L-PBF in producing complex, high-performance aluminum alloy components for industrial use.

Thermo-hydraulic performance evaluation of lattice structures with triply periodic minimal surfaces for latent heat storage devices

Triply periodic minimal surface (TPMS) structures exhibit significant potential in latent heat storage (LHS) applications. In this study, numerical investigations were conducted to study the thermal storage performance of four TPMS lattice types: Primitive, IWP, FRD, and Gyroid lattices, used as metallic skeletons in LHS devices. The volumes of both the TPMS skeletons and the phase change material (PCM) were kept constant, with PCM embedded either inside or outside the lattices. The melting process of PCM, the heat storage energy density, and the power density of the LHS units for different configurations were examined. Additionally, a performance evaluation coefficient was introduced to assess the heat transfer and flow characteristics of heat transfer fluid (HTF) flowing on both sides of the lattices. The results indicated that when using Primitive and FRD lattices, embedding the PCM within the internal space of the lattices resulted in a 20 % and 9.8 % higher energy storage compared to embedding it outside the lattices. The internal space of IWP and Gyroid lattices was more suitable for HTF flow channels, resulting in performance evaluation coefficients (PECs) that improved by 27.7 % and 86.3 %, respectively, when HTF flowed through the internal channels of these lattices. Moreover, the Gyroid lattice exhibited the most balanced overall heat transfer performance due to its minimal flow resistance, whereas the FRD lattice had the lowest flow performance due to its complex structure. Therefore, the Primitive and Gyroid lattices could be considered as new heat transfer structures for LHS devices, while the FRD lattice was more suitable for replacing traditional fin structures in heat sink devices.

Sunflower pith inspired dual-gradient cellular polyurethane architecture with amplified mechanical functions

Artificial cellular materials with various mechanical functions are attracting increasing attentions from aerospace, transportation, and industrialization. However, many artificial cellular materials, despite of the hierarchically ordered structures and even unique performance to some, still lag behind many natural ones in amplification of mechanical functions owing to the limitations in intrinsic mechanical performance and sophisticated structural design. Herein, inspired with lightweight and high strength of sunflower piths, we proposed a dual-gradient structure consisting of pore size gradient and wall thickness gradient to engineer cellular architectures with desirable mechanical performance by harnessing vat photopolymerization 3D printing of double crosslinking networks polyurethane elastomer. The double-gradient cellular polyurethane architecture displays more exceptional capability in load-bearing and energy absorption compared with non– and single gradient structures. Besides, the specific compressive strength and energy absorption of the dual-gradient cellular architectures are 4 times higher than those of traditional mechanical metamaterial structures such as octet-truss lattice, gyroid lattice, and porous structure prepared with the same material. Potential mechanisms such as dual-gradient cellular structures to obtain selective flexural deformation behaviour increasing their energy absorption and dissipation capacity are fully elucidated. As the potential paradigms, we demonstrated the mechanical functions of biomimetic mechanical cellular architectures for efficient impact protection and noise isolation, which offered a promising perspective toward developing soft metamaterials with excellent mechanical functions for potential soft machines and engineering applications.

Electrified reformer for syngas production – Additive manufacturing of coated microchannel monolithic reactor

Here, an electrified reformer with a bespoke design of catalyst-coated and additively manufactured monoliths with 3-D pore architecture is presented. The 2D-pore architecture of the hexagonal honeycomb monolith was compared against the 3D-pore architecture of three broad classifications - triply periodic minimal surface (Gyroid), strut-based (Octet) and stochastic lattice (Voronoi). Gyroid structured reactor, coated with NiO/Ce0.8Gd0.2O2-δ catalyst and heated to 900 °C achieved >99 % conversion of CO2 and CH4 at WHSV = 11,000 L.h−1.kgcat−1, while remaining active for >42 h with no evidence of coke deposition. Whereas Octet and Voronoi reactors showed slightly lower conversions, with 6-fold and 4-fold higher pressure drops, respectively. This study combines Computational Fluid Dynamics and experimental evidence to reveal that the Gyroid lattice provides high catalyst deposition and catalytic activity at low pressure drops. This study demonstrates the feasibility of renewable energy-powered structured reactors to provide a pathway for low carbon footprint chemical production.

Effect of Heat Treatment on Mechanical Properties of 17-4 PH Stainless Steel Gyroid Lattice Structures Manufactured by Selective Laser Melting and a Study on Weight Reduction Methods

Effect of Heat Treatment on Mechanical Properties of 17-4 PH Stainless Steel Gyroid Lattice Structures Manufactured by Selective Laser Melting and a Study on Weight Reduction Methods

Network-based and sheet-based Gyroid lattice structures with different gradient directions: manufacture, mechanical response and energy absorption

Network-based and sheet-based Gyroid lattice structures with different gradient directions: manufacture, mechanical response and energy absorption

Effect of unit cell rotation on mechanical performance of selective laser melted Gyroid structures for bone tissue engineering

Gyroid lattice structures, inspired by the natural interconnectivity of human bone, show promise in bone tissue engineering (BTE). This study explores the mechanical properties, and failure mechanisms of selective laser melted (SLM) Gyroid Ti6Al4V lattice structures with varying unit cell rotation angles (RA) of 0∘ (G0), 30∘ (G30), and 60∘ (G60) around the x-axis. The study assesses their mechanical and energy absorption properties through quasi-static compression testing and elastoplastic finite element (FE) analysis. Despite similar relative densities for all designed lattices, the RA variation significantly impacts mechanical performance. G30 exhibits superior load-bearing capacity, with higher modulus of elasticity, yield strength, ultimate strength, and plateau stress. It also has the highest energy absorption capacity, while G60 shows the highest surface area (SA) and surface area-to-volume ratio (SA/VR). These findings highlight the potential of Gyroid lattices for bone replacements due to their tunable mechanical and biological responses.

Dimensional and mechanical assessment of gyroid lattices produced in aluminum by laser powder bed fusion

Dimensional and mechanical assessment of gyroid lattices produced in aluminum by laser powder bed fusion

ANISOTROPY AND MECHANICAL CHARACTERISTICS OF ULTRA-HIGH PERFORMANCE CONCRETE AND ITS INTERPENETRATING PHASE COMPOSITE WITH TRIPLY PERIODIC MINIMAL SURFACE ARCHITECTURES

Abstract This work numerically explores the anisotropy, impact phase wave propagation, buckling resistance, and natural vibration of ultra-high performance concrete (UHPC) and UHPC-steel interpenetrating phase composite (IPC) with triply periodic minimal surfaces (TPMSs), including sheet and solid Gyroid, Primitive, Diamond, and I-WP. The experiment is conducted verifying the accuracy of the numerical model in terms of Young's modulus of polylactic acid (PLA)-based TPMS lattices and PLA-cement IPCs with TPMS cores, with the highest percent difference of 15% found for IPCs and 17% found for lattice. The results indicate that UHPC material with sheet Gyroid exhibits the least extreme anisotropy in response to the varying orientation among other lattices regardless of the change of solid density, making it the ideal candidate for construction materials. Interestingly, compared to UHPC-based TPMS lattice, IPCs possess a much smaller anisotropy and exhibit almost isotropy regardless the variation of solid density and TPMS topology, offering a free selection of TPMS type to fabricate IPCs without much care of anisotropy. The phase wave and buckling resistance of UHPC- and IPC-based beams with TPMSs nonlinearly decrease with a drop of TPMS solid density, but it is the almost linear pattern for the case of natural vibration frequency. UHPC material and IPC with sheet Gyroid lattice are found to possess the lowest phase wave velocity and exhibit the least anisotropy of wave propagation, showing it as an ideal candidate for UHPC material to suppress the destructive energy induced by the external impact.

Influence of the cell size and wall thickness on the compressive behaviour of fused filament fabricated PLA gyroid structures

The development of Additive Manufacturing (AM) has greatly facilitated the fabrication of cellular and lattice materials. Gyroid-based lattice structures, known for their distinctive properties such as interconnected porosity, high surface-to-volume ratio, and remarkable structural stiffness combined with specific energy absorption, have been extensively explored. Many studies examining the impact of design parameters on the mechanical properties of Gyroid lattice materials have utilized metal AM techniques. This research aims to evaluate the influence of two design parameters on the compressive properties of Gyroid structures obtained by fused filament fabrication (FFF). A full factorial analysis was employed to assess the effects of cell size and wall thickness on the compressive properties of polylactic acid (PLA) Gyroid lattices. Cell sizes were varied between 4 mm, 5 mm, and 10 mm, while wall thickness ranged from 0.4 mm, 0.6 mm, to 0.8 mm. After 3D printing, the print quality was assessed, samples were weighted and then subjected to compression testing. During compression, the lattices with 10 mm cells exhibited successive layer collapse, whereas the lattice with 4 mm and 5 mm cells displayed plastic deformation, marked by a plateau in the stress-strain curve. These behaviours were mostly independent of wall thickness, except for the 5 mm cell lattice with 0.4 mm wall thickness. The elastic modulus, yield stress and absorbed energy per volume aligned with the apparent density of the lattices, ranging between 1% and 12% of the bulk 3D printed material for both the stiffness and yield stress, and between 1% and 22% for the energy absorbed. Analysis of the fitted means indicated that doubling the cell size had a more significant impact on the measured properties than doubling the wall thickness, while doubling both the cell size and wall thickness exerted a more pronounced influence on the yield stress and strain. Notably, under the conditions of this study, the 3D printed PLA Gyroids behaved similarly to closed cell foams, despite their interconnected channels. Their compressive mechanical properties comparable to those of rigid polyurethane foams with closed cells.

Mechanical Properties, Energy Absorption, and Shape Memory Behavior of 3D Printed PLA‐MXene Nanocomposites and Gyroid Lattices

This work investigates the influence of MXene content on the mechanical and functional response of PLA‐MXene composites fabricated additively using fused deposition modeling. The mechanical, thermal, and microstructural properties of the fabricated samples are investigated considering dense and architected triply periodic minimal surfaces (TPMS) gyroid specimens. Overall, the addition of 0.25–0.5 wt% MXene is found to improve the stiffness, fracture strength, and energy absorption capabilities of the PLA. However, further increasing MXene content to 1 wt% becomes detrimental to the general performance of the composite. In terms of functional behavior, the PLA‐MXene blends developed in this work are shown to display a shape memory effect, wherein deformed samples are shown to recover their shape when submerged in hot water. The reported results provide insights into the use of PLA‐MXene in engineering applications, namely those involving impact shielding or energy absorption.

Comparative study on tensile and morphological properties of resin and rice husk reinforced polymer composite gyroid lattice structures

This study aims to compare the tensile behaviour of 3d printed resin and rice husk-reinforced resin-based gyroid lattice structures. The work was completed in two phases, firstly a resin gyroid lattice structure with two design configurations of unit cell sizes (3, 4, 5, and 6) and solidity percentages (30, 40, and 50) was developed according to the ASTM638 (4) standard. The 12 designs were manufactured using VAT polymerization additive manufacturing and investigated for tensile strength. In the second phase, the poorest tensile testing results were chosen to develop the rice husk-reinforced resin samples with a mixing proportion of 10–20%–30%. The experiment results revealed that the fracture is localized inside the gauge length according to the standard. Remarkably, the rice husk composite-based gyroid lattice samples exhibit 4.29, 6.55, and 9.35 times higher tensile strength than the selected resin sample (U3–30). Additionally, a homogeneous distribution of rice husk particles has been observed in the micrograph analysis (SEM).

Optimization of energy absorption and vibration behaviour of TPMS Schwarz P and Schoen Gyroid lattice structures using Taguchi L9 orthogonal array

In this study, the optimization of printing parameters in fused deposition modeling (FDM) is addressed, focusing on their impact on energy absorption and vibration behaviour of triply periodic minimal surface (TPMS) lattice structures, specifically Pseudo-periodic-based Schwarz P and Schoen Gyroid designs. The experimental design employs a Taguchi L9 orthogonal array involving layer height (0.15 mm, 0.30 mm, 0.45 mm), build orientation (0°, 45°, 90°), and extruder temperature (190°C, 200°C, 210°C) as inputs. These lattice structures are generated through Math Mod and simulated using Blender, with Autodesk Mesh mixer refining the STL file. The lattice fabrication employs PLA (polylactic acid). Comparative analysis is conducted against a high-density solid structure lacking lattice design. Optimal parameters for Schwarz P lattice are found to be 0.45 mm layer height, 0° build orientation, and 200°C extruder temperature, while for Schoen Gyroid lattice, 0.30 mm layer height, 0° build orientation, and 210°C extruder temperature. Solid structure optimization yields 0.30 mm layer height, 90° build orientation, and 190°C extruder temperature. Solid structures outperform Schwarz-P and Schoen-Gyroid in energy absorption and vibration behaviour, with Schwarz P showing superior properties over Schoen Gyroid.

Choosing between commercially pure titanium and Ti-6Al-4V gyroid structures for orthopedic applications: An analysis through Timoshenko beam theory, the Gibson-Ashby model and experimental methods

For decades, research has focused on using gyroid lattice structures to prevent stress-induced osteopenia and improve osseointegration by promoting cell adhesion and transition, particularly in cases where implant removal is not desired after complete healing. Despite these advantages, in-depth research is still needed for innovative biomedical implants to reach optimum functionality. Although commercially pure titanium (Cp-Ti) and Ti6Al4V are both popular materials for standalone bone implants, they are not likely paired within the same application due to mechanical property differences. This study proposes a case-specific workflow to support orthopedic implant design considerations, by analytically and experimentally investigating the mechanical response of additively manufactured lattice gyroid structures in both Cp-Ti and Ti6Al4V with different porosity rates. The experimental results of both materials indicate a significant decrease in the elastic modulus against two employed analytical methods, Gibson-Ashby model and Timoshenko beam theory. This is linked to inherent manufacturing-induced stress concentrations on the physical gyroids. The experimental outcome presents itself significantly closer to the predictions of Timoshenko beam theory compared to Gibson Ashby method. Both gyroid titanium structures are loyal to Timoshenko theory, displaying a combination of multi deformation behaviors instead of one-way deformation. The deformation response of Ti6Al4V showed a 45⁰ shear band while Cp-Ti exhibited smoother deformation during compression. Higher porosity rates led to an increase in ductility due to extended horizontal plateau regions in both Cp-Ti and Ti6Al4V lattice structures. The results provide valuable comparative insight and considerations on the material choice for gyroid lattice structures within bone implants.

Comparison of thermo-hydraulic performance among different 3D printed periodic open cellular structures

As additive manufacturing of periodic open cellular structures (POCS) is gaining interest in structured catalytic reactor research, this work seeks to thermohydraulically compare the well-known Kelvin lattice structure with the lesser-researched BCC and gyroid lattice structures. Using a combined CFD (Computational Fluid Dynamic) and experimental approach, the selected POCS are fabricated through Laser Powder Bed Fusion (LPBF), characterized, and subsequently subjected to numerical analysis. From the manufacturability point of view, the 3D printed samples closely matched their CAD designs, showing a maximum porosity deviation of 15% below design values. A CFD model, validated through pressure drop experiment, was employed to compare the POCS designs on shared geometric attributes such as specific surface area and porosity. While all structures exhibited comparable performance in term of heat and momentum transfer, our findings suggest that the Gyroid lattice may provide the optimal balance between momentum and heat transfer rates in low-velocity region. Conversely, the BCC configuration may be more favourable at higher velocity. An Ergun-like correlation was also developed and validated for each lattice type, with a Mean Absolute Percentage Error (MAPE) below 10%. Our pressure drop results align quite well with existing literature correlations, showing a MAPE under 20%. Concerning heat transfer, the values forecasted in this research show a reasonable alignment with literature’s results, though they tend to be on the lower spectrum.

Development of a 3D-printed spongy electrode design for microbial fuel cell (MFC) using gyroid lattice

Microbial fuel cell technology addresses both issues in finding new ways to clean water systems while harnessing electricity. Several studies suggest that a single large-scale MFC is proven to be inefficient and expensive. Therefore, producing small-scale MFCs is focused on investigation to provide an efficient system and cost-effective approach. This study used 3D-printed MFCs using a spongy electrode design to produce a modern approach to modifying electrode capacity in energy generation. Furthermore, the study identifies the electrical conductivity of the spongy electrode by determining the voltage generated and power density by stacked MFCs in series, parallel, and hybrid configurations. The MFCs generate a maximum voltage of 633 mV and a current of 14.22 . One way to reduce the effects of voltage reversal in the MFC system is the application of hybrid connection circuits. Parallel-series hybrid connection possesses stable voltage generation of 250−300 𝑚𝑉 with the highest current generation of 115.20 𝜇𝐴. At the same time, the Series-Parallel Connection generates the highest voltage and current of 259 mV and 30 , respectively. The spongy electrode design and hybrid connection produced a maximum power and current density of 29.30 μW⁄m2 and 279.41 μA⁄m2 obtained from a different connection of pure parallel and 28P-2S hybrid connection. Furthermore, water quality parameters were examined (pH, TDS, ORP, and COD), that the MFCs design is efficient in wastewater treatment, with a %COD removal of 95.24% efficiency, reduced ORP from +48.00 mV to -7.00 mV, and the TDS concentration from 270 ppm to 239 ppm.

Enhanced Energy Absorption with Bioinspired Composite Triply Periodic Minimal Surface Gyroid Lattices Fabricated via Fused Filament Fabrication (FFF)

Bio-inspired gyroid triply periodic minimum surface (TPMS) lattice structures have been the focus of research in automotive engineering because they can absorb a lot of energy and have wider plateau ranges. The main challenge is determining the optimal energy absorption capacity and accurately capturing plastic plateau areas using finite element analysis (FEA). Using nTop’s Boolean subtraction method, this study combined walled TPMS gyroid structures with a normal TPMS gyroid lattice. This made a composite TPMS gyroid lattice (CTG) with relative densities ranging from 14% to 54%. Using ideaMaker 4.2.3 (3DRaise Pro 2) software and the fused deposition modeling (FDM) Raise3D Pro 2 3D printer to print polylactic acid (PLA) bioplastics in 1.75 mm filament made it possible to slice computer-aided design (CAD) models and fabricate 36 lattice samples precisely using a layer-by-layer technique. Shimadzu 100 kN testing equipment was utilized for the mechanical compression experiments. The finite element approach validates the results of mechanical compression testing. Further, a composite CTG was examined using a field emission scanning electron microscope (FE-SEM) before and after compression testing. The composite TPMS gyroid lattice showed potential as shock absorbers for vehicles with relative densities of 33%, 38%, and 54%. The Gibson–Ashby model showed that the composite TPMS gyroid lattice deformed mainly by bending, and the size effect was seen when the relative densities were less than 15%. The lattice’s relative density had a significant impact on its ability to absorb energy. The research also explored the use of these innovative foam-like composite TPMS gyroid lattices in high-speed crash box scenarios to potentially enhance vehicle safety and performance. The structures have tremendous potential to improve vehicle safety by acting as advanced shock absorbers, which are particularly effective at higher relative densities.

Zeolite-coated 3D-printed gyroid scaffolds for carbon dioxide adsorption

3D-printed adsorbents are gaining increased attention owing to their potential in overcoming operational challenges faced by the conventionally structured counterparts. In this work, cylindrical scaffolds of triply periodic minimal surface (TPMS) configuration were synthesized using 3D-printing by stereolithography. This unique gyroid sheet TPMS network was selected as it offers a high surface-area-to-volume ratio. The surface of the scaffolds was modified by a silanization process followed by coating via grafting with zeolite 13X crystals toward CO2 adsorption application. A secondary zeolite coating step was also employed to enhance the zeolite 13X loading, resulting in zeolite loadings of 16 wt% and 23 wt% after the primary and secondary coatings, respectively. Following morphological and structural characterization, the CO2 adsorption performance of the 3D-printed materials was evaluated with respect to adsorption capacity, kinetics, selectivity, and heat of adsorption. Cyclic stability was also assessed over CO2 adsorption–desorption pressure swing adsorption cycles at 25 °C. Comparative analysis showed that the 3D-printed coated samples exhibited higher CO2/N2 selectivity and improved cyclic stability with a slightly lower CO2 adsorption capacity than the zeolite 13X powder. The heat of adsorption ranged from 18 to 41 kJ mol−1 for both the powder and the coated adsorbents, indicating physisorption. The gyroid lattice of the 3D-printed structures, featuring a densely arranged network of smooth, interconnected flow channels, facilitated molecular transport thus yielding higher CO2 adsorption kinetics than the powder. Indicatively, the primary and secondary coatings attained an equilibrium capacity of 4 mmol g−1 at 25 °C in 62 and 57 min, respectively, while the powder required 110 min at the same conditions. The 3D-printed materials exhibited also significantly higher CO2/N2 selectivity values of 569 and 115 at 50 mbar and 1 bar, respectively, for the primary coating sample, and 536 and 73 at 50 mbar and 1 bar, respectively, for the secondary coating one. The findings highlight the potential of 3D-printing to produce coated structured adsorbents with complex geometries for sustainable CO2 capture and gas adsorption processes.

Design and Development of Novel Lattice Structures for Optimum Energy Absorption

Abstract Lattice structures are intricate networks of interconnected struts, surfaces, and plates formed from irregular and non-periodic cells. Among the promising lattices, triply periodic minimal surfaces (TPMS) lattices stand out for their attractive blend of lightweight properties, excellent energy absorption capacity, and thermal insulation capabilities. In this paper, we propose a modeling technique to create innovative lattice structures with complicated shapes and compare their mechanical properties with existing TPMS lattices. The lattice is coded in matlab using mathematical equations. The filament-based material extrusion method was utilized to produce the desired lattice structures. In order to determine the compressive mechanical properties, the 3D-printed lattices underwent compression testing. The energy absorption capacity of the novel lattices was shown to be increased by 135%, 153%, and 162% when compared to gyroid lattice structures and 110%, 125%, and 132% when compared to diamond lattice structures at constant relative density. Furthermore, this technique gives data for creating lattice structures with complicated contours as well as the underlying design principles for the construction of lattice structures with superior mechanical characteristics and numerous applications, particularly in protective devices. The proposed approach could be used in the future to develop lightweight structures for biomedical applications that incorporate various lattice unit cell designs.