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Experimental and numerical investigation of PLA based different lattice topologies and unit cell configurations for additive manufacturing

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Abstract

Lattice structures are bio-inspired designs made up of repeated unit cells consisting of beams, surfaces, or plates that fit together in an ordered or stochastic fashion. These unit cells are configured according to their size and shape in three dimensions. Simple lattices can be created using standard manufacturing techniques such as computer numerical control machining, welding, and casting. Additive manufacturing enables customers to make complex structures with small features at a reasonable cost. In the present work, using octagon, hexagrid, and rhombic dodecahedron lattice topologies, characterized by unit cell size from 3 × 3 × 3 to 7 × 7 × 7 mm and strut thickness from 0.5 to 1.5 mm, the structural behavior of a solid cylindrical model made of polylactic acid material under compression is analyzed. Finite element analysis (FEA) through Autodesk® Netfabb® solvers was used to assess lattice structure mechanical and structural properties. The results were validated by physical compression testing on additively manufactured samples. Cellular designs with 3 × 3 × 3 mm unit cells and 1.5 mm strut thickness displayed the lowest Von Mises stress and deformation. For different topologies, lowest results were rhombic dodecahedron (stress through FEA as 61.3108 MPa and stress through physical test as 61.05 MPa, deformation through FEA as 0.49921 mm and deformation through physical test as 0.48 mm), octagon (stress through FEA as 77.4147 MPa and stress through physical test as 76.92 MPa, deformation through FEA as 0.53316 mm and deformation through physical test as 0.51 mm), and for hexagrid (stress through FEA as 62.2911 MPa, stress through physical test as 62.15 MPa, deformation through FEA as 0.81997 mm and deformation through physical test as 0.81 mm). The percentage error between the stress through FEA and stress through physical test for octagon, hexagrid, and rhombic dodecahedron lattice topology was found out to be 0.63, 0.22, and 0.43%, respectively. Corresponding percentage deformation error between deformation through FEA and deformation through physical test was also found out to be 4.343, 2.435, and 3.848%, respectively. In addition, the impacts of volume reduction, surface area of the lattice, and relative density were explored pertaining to the structural behavior of the lattice. As a result of the examination into mechanical qualities based on these criteria, rhombic dodecahedron lattice topology with 3 × 3 × 3 mm unit cell size and strut thickness of 1.5 mm was found to be a better choice than octagon and hexagrid lattice topologies for 3D printing components that were loaded under axially compressive loads.

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Data availability

The data that support the findings of this study are available from the corresponding author (CM) upon reasonable request.

Abbreviations

PLA:

Polylactic acid

FEA:

Finite element analysis

σ FEA :

Von-Mises stress obtained through FEA

σ Physical  Test :

Stress obtained through physical test

Δl FEA :

Deformation obtained through FEA

Δl Physical  Test :

Deformation obtained through physical test

AM:

Additive manufacturing

SAC:

Surface area coefficient

VRC:

Volume reduction coefficient

TPMS:

Triply periodic minimal surfaces

LBC:

Lattice beam count

LPC:

Lattice polygon count

U :

Strain energy

NABL:

National Accreditation Board for Testing and Calibration Laboratories

E :

Young’s modulus of PLA

σ :

Compressive strength of PLA

µ :

Poisson’s ratio

ρ :

Density

ISO:

International Organization for Standardization

ε 40 % :

40% Strain

FDM:

Fused deposition modeling

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Acknowledgements

The authors acknowledge the financial support through the Researchers Supporting Project number (RSPD2024R724), King Saud University, Riyadh, Saudi Arabia.

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Authors and Affiliations

  1. Yeshwantrao Chavan College of Engineering, Nagpur, 441110, India

    Chetan Mahatme, Jayant Giri, Neeraj Sunheriya & Rajkumar Chadge

  2. Department of Chemistry, College of Science, King Saud University, P.O. Box 2455, Riyadh, 11451, Kingdom of Saudi Arabia

    Faruq Mohammad & Mohd Sajid Ali

  3. Saveetha School of Engineering, SIMATS, Chennai, 602 105, Tamil Nadu, India

    Thanikodi Sathish

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  1. Chetan Mahatme
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  2. Jayant Giri
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  3. Faruq Mohammad
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  4. Mohd Sajid Ali
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  5. Thanikodi Sathish
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  6. Neeraj Sunheriya
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  7. Rajkumar Chadge
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Contributions

All authors contributed equally to the conceptualization, formal analysis, investigation, methodology, and writing and editing of the original draft. All authors have read and agreed to the published version of the manuscript.

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Correspondence to Chetan Mahatme.

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Mahatme, C., Giri, J., Mohammad, F. et al. Experimental and numerical investigation of PLA based different lattice topologies and unit cell configurations for additive manufacturing. Int J Adv Manuf Technol (2024). https://doi.org/10.1007/s00170-024-13882-4

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