Stress Concentration and Mechanical Strength of Cubic Lattice Architectures

Improved Mechanical Performance in FDM Cellular Frame Structures through Partial Incorporation of Faces

The utilization of lattice-type cellular architectures has seen a significant increase, owing to their predictable shape and the ability to fabricate templated porous materials through low-cost 3D-printing methods. Frames based on atomic lattice structures such as face-centered cubic (FCC), body-centered cubic (BCC), or simple cubic (SC) have been utilized. In FDM, the mechanical performance has been impeded by stress concentration at the nodes and melt-solidification interfaces arising from layer-by-layer deposition. Adding plates to the frames has resulted in improvements with a concurrent increase in weight and hot-pocket-induced dimensional impact in the closed cells formed. In this paper, we explore compressive performance from the partial addition of plates to the frames of a SC-BCC lattice. Compression testing of both single unit cells and 4 × 4 × 4 lattices in all three axial directions is conducted to examine stress transfer to the nearest neighbor and assess scale-up stress transfer. Our findings reveal that hybrid lattice structure unit cells exhibit significantly improved modulus in the range of 125% to 393%, specific modulus in the range of 13% to 120%, and energy absorption in the range of 17% to 395% over the open lattice. The scaled-up lattice modulus increased by 8% to 400%, specific modulus by 2% to 107%, and energy absorption by 37% to 553% over the lattice frame. Parameters that emerged as key to improved lightweighting.

3D-Printed lattice-inspired composites for bone reconstruction

Mechanical performance is crucial for biomedical applications of scaffolds. In this study, the stress distribution of six lattice-inspired structures was investigated using finite element simulations, and scaffolds with pre-designed structures were prepared using selective laser sintering (SLS) technology. The results showed that scaffolds with face-centered cubic (FCC) structures exhibited the highest compressive strength. Moreover, scaffolds composed of polylactic acid/anhydrous calcium hydrogen phosphate (PLA/DCPA) showed good mechanical properties and bioactivity. An in vitro study showed that these scaffolds promoted cell proliferation significantly and showed excellent osteogenic performance. Composite scaffolds with FCC structures are promising for bone tissue engineering.

Numerical investigation of the effective mechanical properties and local stress distributions of TPMS-based and strut-based lattices for biomedical applications

Porous structures, including those with lattice geometries, have been shown to mimic the mechanical properties of the human bone. Apart from the widely known strut-based lattices, the Triply Periodic Minimal Surfaces (TPMS) concept has been introduced recently to create surface-based lattices and to tailor their mechanical behaviors. In this study, the numerical investigation of the effective elastic properties, the anisotropic behavior, and the local stress distributions of a broad range of topologies provide us with a complete numerical tool to assist bone implant design. The comparison database of the lattices includes TPMS-based lattices, both sheet, and skeletal, as well as strut-based lattices. The lattices are subjected to periodic boundary conditions and also, a homogenization method is deployed to simulate the response of the lattice unit cells determining their apparent equivalent stiffness. A correlation among the lattice topologies, their effective mechanical properties, and the local Von Mises stress concentrations in them is observed. The stress distribution of various topologies with the same elastic modulus is examined to combine all the investigations. Finally, a large variety of numerical results are presented to allow the comparison of the lattice structures and the selection of the optimal configuration that mimics the elastic properties of the bone.

Generalized tessellations of superellipitcal voids in low porosity architected materials for stress mitigation

Stress concentration is a crucial source of mechanical failure in structural elements, especially those embedding voids. This paper examines periodic porous materials with porosity lower than 5%. We investigate their stress distribution under planar multiaxial loading, and presents a family of geometrically optimized void shapes for stress mitigation. We adopt a generalized description for both void geometry and planar tessellation patterns that can handle single and multiple voids of arbitrary void shape at a generic angle. The role of void shape evolution from diamond to rectellipse on the stress-distribution is captured at the edge of voids in a representative volume element (RVE) made of non-equal length periodic vectors. Theoretical derivations, numerical simulations along with experimental validation of the strain field in thermoplastic polymer samples fabricated by laser cutting unveil the role of geometric parameters, e.g. superellipse order, aspect ratio and rotation angle, that minimize stress peak and ameliorate stress distribution around voids. This work extends and complements classical theory by providing fundamental insights into the role that tessellation, void shape and inclination play in the stress distribution of low-porosity architected materials, thus introducing essential guidelines of broad application for stress-minimization and failure mitigation in diverse sectors.

Mechanical performance of highly permeable laser melted Ti6Al4V bone scaffolds

Critically engineered stiffness and strength of a scaffold are crucial for managing maladapted stress concentration and reducing stress shielding. At the same time, suitable porosity and permeability are key to facilitate biological activities associated with bone growth and nutrient delivery. A systematic balance of all these parameters are required for the development of an effective bone scaffold. Traditionally, the approach has been to study each of these parameters in isolation without considering their interdependence to achieve specific properties at a certain porosity. The purpose of this study is to undertake a holistic investigation considering the stiffness, strength, permeability, and stress concentration of six scaffold architectures featuring a 68.46-90.98% porosity. With an initial target of a tibial host segment, the permeability was characterised using Computational Fluid Dynamics (CFD) in conjunction with Darcy's law. Following this, Ashby's criterion, experimental tests, and Finite Element Method (FEM) were employed to study the mechanical behaviour and their interdependencies under uniaxial compression. The FE model was validated and further extended to study the influence of stress concentration on both the stiffness and strength of the scaffolds. The results showed that the pore shape can influence permeability, stiffness, strength, and the stress concentration factor of Ti6Al4V bone scaffolds. Furthermore, the numerical results demonstrate the effect to which structural performance of highly porous scaffolds deviate, as a result of the Selective Laser Melting (SLM) process. In addition, the study demonstrates that stiffness and strength of bone scaffold at a targeted porosity is linked to the pore shape and the associated stress concentration allowing to exploit the design freedom associated with SLM.