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Zhu C, Gemeda HB, Duoss EB, Spadaccini CM. Toward Multiscale, Multimaterial 3D Printing. ADVANCED MATERIALS (DEERFIELD BEACH, FLA.) 2024; 36:e2314204. [PMID: 38775924 DOI: 10.1002/adma.202314204] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Subscribe] [Scholar Register] [Received: 12/26/2023] [Revised: 04/11/2024] [Indexed: 06/06/2024]
Abstract
Biological materials and organisms possess the fundamental ability to self-organize, through which different components are assembled from the molecular level up to hierarchical structures with superior mechanical properties and multifunctionalities. These complex composites inspire material scientists to design new engineered materials by integrating multiple ingredients and structures over a wide range. Additive manufacturing, also known as 3D printing, has advantages with respect to fabricating multiscale and multi-material structures. The need for multifunctional materials is driving 3D printing techniques toward arbitrary 3D architectures with the next level of complexity. In this paper, the aim is to highlight key features of those 3D printing techniques that can produce either multiscale or multimaterial structures, including innovations in printing methods, materials processing approaches, and hardware improvements. Several issues and challenges related to current methods are discussed. Ultimately, the authors also provide their perspective on how to realize the combination of multiscale and multimaterial capabilities in 3D printing processes and future directions based on emerging research.
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Affiliation(s)
- Cheng Zhu
- Center for Engineered Materials and Manufacturing, Materials Engineering Division, Lawrence Livermore National Laboratory, 7000 East Ave, Livermore, CA, 94550, USA
| | - Hawi B Gemeda
- Center for Engineered Materials and Manufacturing, Materials Engineering Division, Lawrence Livermore National Laboratory, 7000 East Ave, Livermore, CA, 94550, USA
| | - Eric B Duoss
- Center for Engineered Materials and Manufacturing, Materials Engineering Division, Lawrence Livermore National Laboratory, 7000 East Ave, Livermore, CA, 94550, USA
| | - Christopher M Spadaccini
- Center for Engineered Materials and Manufacturing, Materials Engineering Division, Lawrence Livermore National Laboratory, 7000 East Ave, Livermore, CA, 94550, USA
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Vafaeefar M, Moerman KM, Vaughan TJ. Experimental and computational analysis of energy absorption characteristics of three biomimetic lattice structures under compression. J Mech Behav Biomed Mater 2024; 151:106328. [PMID: 38184929 DOI: 10.1016/j.jmbbm.2023.106328] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [MESH Headings] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 08/25/2023] [Revised: 12/08/2023] [Accepted: 12/12/2023] [Indexed: 01/09/2024]
Abstract
The objective of this study is to evaluate the mechanical properties and energy absorption characteristics of the gyroid, dual-lattice and spinodoid structures, as biomimetic lattices, through finite element analysis and experimental characterisation. As part of the study, gyroid and dual-lattice structures at 10% volume fraction were 3D-printed using an elastic resin, and mechanically tested under uniaxial compression. Computational models were calibrated to the observed experimental data and the response of higher volume fraction structures were simulated in an explicit finite element solver. Stress-strain data of groups of lattices at different volume fractions were studied and energy absorption parameters including total energy absorbed per unit volume, energy absorption efficiency and onset of densification strain were calculated. Also, the structures were characterized into bending-dominant and stretch-dominant structures, according to their nodal connectivity and Gibson-and-Ashby's law. The results of the study showed that the dual-lattice is capable of absorbing more energy at each volume fraction cohort. However, gyroid structures showed higher energy absorption efficiency and the onset of densification at higher strains. The spinodoid structure was found to be the poorest structure in terms of energy absorption, specifically at low volume fractions. Also, the results showed that the dual-lattice was a stretch dominated structure, while the gyroid structure was a bending dominated structure, which may be a reason that it is a better candidate for energy absorption applications.
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Affiliation(s)
- Mahtab Vafaeefar
- Biomechanics Research Centre (BMEC), School of Engineering, College of Science and Engineering, University of Galway, Ireland
| | - Kevin M Moerman
- Mechanical Engineering, School of Engineering, College of Science and Engineering, University of Galway, Ireland; Griffith Centre of Biomedical and Rehabilitation Engineering (GCORE), Griffith University, Gold Coast, Australia.
| | - Ted J Vaughan
- Biomechanics Research Centre (BMEC), School of Engineering, College of Science and Engineering, University of Galway, Ireland.
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Haney CW, Siller HR. Properties of Hyper-Elastic-Graded Triply Periodic Minimal Surfaces. Polymers (Basel) 2023; 15:4475. [PMID: 38231890 PMCID: PMC10707849 DOI: 10.3390/polym15234475] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Received: 10/02/2023] [Revised: 11/17/2023] [Accepted: 11/17/2023] [Indexed: 01/19/2024] Open
Abstract
The mechanical behaviors of three distinct lattice structures-Diamond, Gyroid, and Schwarz-synthesized through vat polymerization, were meticulously analyzed. This study aimed to elucidate the intricacies of these structures in terms of their stress-strain responses, energy absorption, and recovery characteristics. Utilizing the described experiments and analytical approaches, it was discerned, via the described experimental and analytical procedure, that the AM lattices showcased mechanical properties and stress-strain behaviors that notably surpassed theoretical predictions, pointing to substantial disparities between conventional models and experimental outcomes. The Diamond lattice displayed superior stiffness with higher average loading and unloading moduli and heightened energy absorption and dissipation rates, followed by the Gyroid and Schwarz lattices. The Schwarz lattice showed the most consistent mechanical response, while the Diamond and Gyroid showed capabilities of reaching larger strains and stresses. All uniaxial cyclic compressive tests were performed at room temperature with no dwell times. The efficacy of hyper-elastic-graded models significantly outperformed projections offered by traditional Ashby-Gibson models, emphasizing the need for more refined models to accurately delineate the behaviors of additively manufactured lattices in advanced engineering applications.
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Affiliation(s)
| | - Hector R. Siller
- Department of Mechanical Engineering, University of North Texas, 3940 N. Elm Str., Denton, TX 76207, USA;
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Wang S, Xia H. Protective Behaviors of Bio-Inspired Honeycomb Column Thin-Walled Structure against RC Slab under Impact Loading. Biomimetics (Basel) 2023; 8:biomimetics8010073. [PMID: 36810404 PMCID: PMC9944957 DOI: 10.3390/biomimetics8010073] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 12/16/2022] [Revised: 01/22/2023] [Accepted: 02/02/2023] [Indexed: 02/12/2023] Open
Abstract
In order to protect the reinforced concrete (RC) slab structure from damage under some accidental conditions, such as impacting and explosion, we used bio-inspired honeycomb column thin-walled structure (BHTS) to serve as a buffer interlayer for the concrete structure inspired by the biological structure of beetle's elytra. The mechanical properties of AlSi10Mg used to fabricate the BHTS buffer interlayer were determined by low- and medium-speed uniaxial compression tests and numerical simulations. Subsequently, based on the drop weight impact test models, the effect of the buffer interlayer on the response of the RC slab under the drop weight tests with different energy input was compared by the impact force and duration, maximum displacement and residual displacement, energy absorption (EA), energy proportion, and other indicators. The results show that the proposed BHTS buffer interlayer has a very significant protection effect on the RC slab under the impact of the drop hammer. Due to its superior performance, the proposed BHTS buffer interlayer provides a promising solution for EA of augmented cellular structures widely used in defensive structural components, such as floor slabs, building walls, etc.
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Affiliation(s)
- Shijie Wang
- College of Civil and Architectural Engineering, Heilongjiang Institute of Technology, Harbin 150050, China
| | - Hongxiang Xia
- School of Civil Engineering, Northeast Forestry University, Harbin 150040, China
- Correspondence:
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Hrițuc A, Mihalache AM, Dodun O, Slătineanu L, Nagîț G. Evaluation of Thin Wall Milling Ability Using Disc Cutters. MICROMACHINES 2023; 14:341. [PMID: 36838041 PMCID: PMC9958652 DOI: 10.3390/mi14020341] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Subscribe] [Scholar Register] [Received: 01/04/2023] [Revised: 01/22/2023] [Accepted: 01/25/2023] [Indexed: 06/18/2023]
Abstract
In some cases, industrial practice requires the production of walls or parts with a thickness of less than one millimeter from a metal workpiece. Such parts or walls can be made by milling using disc cutters. This machining method can lead to the generation of residual stresses that determine the appearance of a form deviation characterized by bending the part or the thin wall. To evaluate the suitability of a metallic material for the manufacturing of thin walls by milling with disc cutters, different factors capable of exerting influence on the deviation generated by the residual deformation of the walls were taken into account. A test sample and an experimental research program were designed for the purpose of obtaining an empirical mathematical model. The empirical mathematical model highlights the magnitude of the influence exerted by different input factors on the disc cutter milling process regarding the size of the deviation from the form, and the correct position of the wall or thin part, in the case of a test sample workpiece made of an aluminum alloy. Input factors considered were cutting speed, feed rate, cutter thickness, wall or part thickness, thin wall length, and height. To rank the input factors whose increase leads to an increase in shape deviation, the values of the exponents attached to the factors in question in the empirical mathematical model of the power-type function were taken into account. It was found that the values of the exponents are in the order 0.782 > 0.319 > 0.169 for wall height, feed rate, and wall width, respectively. It was thus established that the strongest influence on the residual deformation of the thin wall is exerted by its height.
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Diosdado-De la Peña JA, Dwyer CM, Krzeminski D, MacDonald E, Saldaña-Robles A, Cortes P, Choo K. Low Impact Velocity Modeling of 3D Printed Spatially Graded Elastomeric Lattices. Polymers (Basel) 2022; 14:4780. [PMID: 36365770 PMCID: PMC9654194 DOI: 10.3390/polym14214780] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Figures] [Journal Information] [Subscribe] [Scholar Register] [Received: 09/30/2022] [Revised: 10/25/2022] [Accepted: 11/03/2022] [Indexed: 09/08/2024] Open
Abstract
Additive manufacturing technologies have facilitated the construction of intricate geometries, which otherwise would be an extenuating task to accomplish by using traditional processes. Particularly, this work addresses the manufacturing, testing, and modeling of thermoplastic polyurethane (TPU) lattices. Here, a discussion of different unit cells found in the literature is presented, along with the based materials used by other authors and the tests performed in diverse studies, from which a necessity to improve the dynamic modeling of polymeric lattices was identified. This research focused on the experimental and numerical analysis of elastomeric lattices under quasi-static and dynamic compressive loads, using a Kelvin unit cell to design and build non-graded and spatially side-graded lattices. The base material behavior was fitted to an Ogden 3rd-order hyperelastic material model and used as input for the numerical work through finite element analysis (FEA). The quasi-static and impact loading FEA results from the lattices showed a good agreement with the experimental data, and by using the validated simulation methodology, additional special cases were simulated and compared. Finally, the information extracted from FEA allowed for a comparison of the performance of the lattice configurations considered herein.
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Affiliation(s)
| | - Charles M. Dwyer
- Advanced Manufacturing Research Center, Youngstown State University, Youngstown, OH 44555, USA
| | | | - Eric MacDonald
- College of Engineering, University of Texas at El Paso, El Paso, TX 79968, USA
| | - Alberto Saldaña-Robles
- Department of Agricultural Mechanical Engineering, University of Guanajuato, Irapuato 36500, Guanajuato, Mexico
| | - Pedro Cortes
- Advanced Manufacturing Research Center, Youngstown State University, Youngstown, OH 44555, USA
| | - Kyosung Choo
- Mechanical Engineering, Youngstown State University, Youngstown, OH 44555, USA
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A Hybrid Level Set Method for the Topology Optimization of Functionally Graded Structures. MATERIALS 2022; 15:ma15134483. [PMID: 35806609 PMCID: PMC9267375 DOI: 10.3390/ma15134483] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 05/17/2022] [Revised: 06/17/2022] [Accepted: 06/21/2022] [Indexed: 11/17/2022]
Abstract
This paper presents a hybrid level set method (HLSM) to design novelty functionally graded structures (FGSs) with complex macroscopic graded patterns. The hybrid level set function (HLSF) is constructed to parametrically model the macro unit cells by introducing the affine concept of convex optimization theory. The global weight coefficients on macro unit cell nodes and the local weight coefficients within the macro unit cell are defined as master and slave design variables, respectively. The local design variables are interpolated by the global design variables to guarantee the C0 continuity of neighboring unit cells. A HLSM-based topology optimization model for the FGSs is established to maximize structural stiffness. The optimization model is solved by the optimality criteria (OC) algorithm. Two typical FGSs design problems are investigated, including thin-walled stiffened structures (TWSSs) and functionally graded cellular structures (FGCSs). In addition, additively manufactured FGCSs with different core layers are tested for bending performance. Numerical examples show that the HLSM is effective for designing FGSs like TWSSs and FGCSs. The bending tests prove that FGSs designed using HLSM are have a high performance.
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Hao F, Maimaitiyiming X. Fast 3D Printing with Chitosan/Polyvinyl alcohol/Graphene Oxide Multifunctional Hydrogel Ink that has UltraStretch Properity. ChemistrySelect 2022. [DOI: 10.1002/slct.202200201] [Citation(s) in RCA: 0] [Impact Index Per Article: 0] [Reference Citation Analysis] [Track Full Text] [Journal Information] [Subscribe] [Scholar Register] [Indexed: 11/11/2022]
Affiliation(s)
- Feiyue Hao
- State Key Laboratory of Chemistry and Utilization of Carbon Based Energy Resources College of Chemistry Xinjiang University, Urumqi 830046 PR China Huaguang Street, Shuimogou District Urumqi Xinjiang Uygur Autonomous Region, China
| | - Xieraili Maimaitiyiming
- State Key Laboratory of Chemistry and Utilization of Carbon Based Energy Resources College of Chemistry Xinjiang University, Urumqi 830046 PR China Huaguang Street, Shuimogou District Urumqi Xinjiang Uygur Autonomous Region, China
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Valle R, Pincheira G, Tuninetti V, Fernandez E, Uribe-Lam E. Design and Characterization of Asymmetric Cell Structure of Auxetic Material for Predictable Directional Mechanical Response. MATERIALS 2022; 15:ma15051841. [PMID: 35269072 PMCID: PMC8911980 DOI: 10.3390/ma15051841] [Citation(s) in RCA: 1] [Impact Index Per Article: 0.5] [Reference Citation Analysis] [Abstract] [Key Words] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 10/21/2021] [Revised: 01/13/2022] [Accepted: 02/07/2022] [Indexed: 12/15/2022]
Abstract
A three-dimensional auxetic structure based on a known planar configuration including a design parameter producing asymmetry is proposed in this study. The auxetic cell is designed by topology analysis using classical Timoshenko beam theory in order to obtain the required orthotropic elastic properties. Samples of the structure are fabricated using the ABSplus fused filament technique and subsequently tested under quasi-static compression to statistically determine the Poisson’s ratio and Young’s modulus. The experimental results show good agreement with the topological analysis and reveal that the proposed structure can adequately provide different elastic properties in its three orthogonal directions. In addition, three point bending tests were carried out to determine the mechanical behavior of this cellular structure. The results show that this auxetic cell influences the macrostructure to exhibit different stiffness behavior in three working directions.
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Affiliation(s)
- Rodrigo Valle
- Faculty of Engineering, University of Talca, Talca 3340000, Chile;
| | - Gonzalo Pincheira
- Department of Industrial Technologies, Faculty of Engineering, University of Talca, Talca 3340000, Chile
- Correspondence:
| | - Víctor Tuninetti
- Department of Mechanical Engineering, Universidad de La Frontera, Francisco Salazar 01145, Temuco 4780000, Chile;
| | - Eduardo Fernandez
- Department of Aerospace and Mechanical Engineering, University of Liege, 4000 Liege, Belgium;
| | - Esmeralda Uribe-Lam
- Tecnológico de Monterrey, Escuela de Ingeniería y Ciencias, Querétaro 76130, Mexico;
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Al Nashar M, Sutradhar A. Design of Hierarchical Architected Lattices for Enhanced Energy Absorption. MATERIALS (BASEL, SWITZERLAND) 2021; 14:5384. [PMID: 34576608 PMCID: PMC8470769 DOI: 10.3390/ma14185384] [Citation(s) in RCA: 4] [Impact Index Per Article: 1.3] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 08/10/2021] [Revised: 09/04/2021] [Accepted: 09/13/2021] [Indexed: 11/16/2022]
Abstract
Hierarchical lattices are structures composed of self-similar or dissimilar architected metamaterials that span multiple length scales. Hierarchical lattices have superior and tunable properties when compared to conventional lattices, and thus, open the door for a wide range of material property manipulation and optimization. Using finite element analysis, we investigate the energy absorption capabilities of 3D hierarchical lattices for various unit cells under low strain rates and loads. In this study, we use fused deposition modeling (FDM) 3D printing to fabricate a dog bone specimen and extract the mechanical properties of thermoplastic polyurethane (TPU) 85A with a hundred percent infill printed along the direction of tensile loading. With the numerical results, we observed that the energy absorption performance of the octet lattice can be enhanced four to five times by introducing a hierarchy in the structure. Conventional energy absorption structures such as foams and lattices have demonstrated their effectiveness and strengths; this research aims at expanding the design domain of energy absorption structures by exploiting 3D hierarchical lattices. The result of introducing a hierarchy to a lattice on the energy absorption performance is investigated by varying the hierarchical order from a first-order octet to a second-order octet. In addition, the effect of relative density on the energy absorption is isolated by creating a comparison between a first-order octet lattice with an equivalent relative density as a second-order octet lattice. The compression behaviors for the second order octet, dodecahedron, and truncated octahedron are studied. The effect of changing the cross-sectional geometry of the lattice members with respect to the energy absorption performance is investigated. Changing the orientation of the second-order cells from 0 to 45 degrees has a considerable impact on the force-displacement curve, providing a 20% increase in energy absorption for the second-order octet. Analytical solutions of the effective elasticity modulus for the first- and second-order octet lattices are compared to validate the simulations. The findings of this paper and the provided understanding will aid future works in lattice design optimization for energy absorption.
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Affiliation(s)
| | - Alok Sutradhar
- Department of Mechanical and Aerospace Engineering, The Ohio State University, Columbus, OH 43210, USA;
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Jing C, Zhu Y, Wang J, Wang F, Lu J, Liu C. Investigation on Morphology and Mechanical Properties of Rod Units in Lattice Structures Fabricated by Selective Laser Melting. MATERIALS (BASEL, SWITZERLAND) 2021; 14:3994. [PMID: 34300910 PMCID: PMC8304159 DOI: 10.3390/ma14143994] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Key Words] [Grants] [Track Full Text] [Download PDF] [Figures] [Subscribe] [Scholar Register] [Received: 06/22/2021] [Revised: 07/05/2021] [Accepted: 07/12/2021] [Indexed: 01/11/2023]
Abstract
Selective laser melting (SLM) fabrication of lattice structures has attracted considerable interest due to its many immanent advantages, such as high specific strength. A wide variety of lattice structures have been designed and fabricated. However, as a vital prerequisite for design optimization, a clear relation between the process constraint of SLM and the apparent properties of the fabricated lattice structure has received much less attention. Therefore, this work systematically investigates the characterization and preformation of rod units, which are the basic components of lattice structures, so as to evaluate the SLM manufacturability of lattice structures. A series of rod units with different inclination angles and diameters were fabricated by SLM. Their morphology and mechanical properties were measured by scanning electron microscope observation and a tensile test, respectively. The inclination angle was found to have significant effects on profile error and little effect on mechanical properties. The higher the inclination angle, the larger the profile error. The characteristic diameter had no significant correlation with profile errors and mechanical properties. Based on systematic studies, a formula is proposed to evaluate the cross-sectional area of the fabricated rod units and further estimate their load capacity. This has important implications for optimizing the design of lattice structures fabricated by SLM.
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Affiliation(s)
- Chenchen Jing
- School of Mechanical Engineering, Beijing Institute of Technology, Beijing 100081, China; (C.J.); (Y.Z.); (J.L.)
| | - Yanyan Zhu
- School of Mechanical Engineering, Beijing Institute of Technology, Beijing 100081, China; (C.J.); (Y.Z.); (J.L.)
| | - Jie Wang
- China Academy of Launch Vehicle Technology, Beijing Institute of Astronautical Systems Engineering, Beijing 100076, China; (J.W.); (F.W.)
| | - Feifan Wang
- China Academy of Launch Vehicle Technology, Beijing Institute of Astronautical Systems Engineering, Beijing 100076, China; (J.W.); (F.W.)
| | - Jiping Lu
- School of Mechanical Engineering, Beijing Institute of Technology, Beijing 100081, China; (C.J.); (Y.Z.); (J.L.)
| | - Changmeng Liu
- School of Mechanical Engineering, Beijing Institute of Technology, Beijing 100081, China; (C.J.); (Y.Z.); (J.L.)
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Geometrical Degrees of Freedom for Cellular Structures Generation: A New Classification Paradigm. APPLIED SCIENCES-BASEL 2021. [DOI: 10.3390/app11093845] [Citation(s) in RCA: 3] [Impact Index Per Article: 1.0] [Reference Citation Analysis] [Abstract] [Track Full Text] [Subscribe] [Scholar Register] [Indexed: 12/15/2022]
Abstract
Cellular structures (CSs) have been used extensively in recent years, as they offer a unique range of design freedoms. They can be deployed to create parts that can be lightweight by introducing controlled porous features, while still retaining or improving their mechanical, thermal, or even vibrational properties. Recent advancements in additive manufacturing (AM) technologies have helped to increase the feasibility and adoption of cellular structures. The layer-by-layer manufacturing approach offered by AM is ideal for fabricating CSs, with the cost of such parts being largely independent of complexity. There is a growing body of literature concerning CSs made via AM; this presents an opportunity to review the state-of-the-art in this domain and to showcase opportunities in design and manufacturing. This review will propose a novel way of classifying cellular structures by isolating their Geometrical Degrees of Freedom (GDoFs) and will explore the recent innovations in additively manufactured CSs. Based on the present work, the design inputs that are common in CSs generation will be highlighted. Furthermore, the work explores examples of how design inputs have been used to drive the design domain through various case studies. Finally, the review will highlight the manufacturability limitations of CSs in AM.
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