Review of defects in lattice structures manufactured by powder bed fusion

• Published in: International journal of advanced manufacturing technology Vol. 106; no. 5-6; pp. 2649 - 2668
• Main Authors: Echeta, Ifeanyichukwu, Feng, Xiaobing, Dutton, Ben, Leach, Richard, Piano, Samanta
• Format: Journal Article
• Language: English
• Published: London Springer London 01.01.2020; Springer Nature B.V
• Subjects: Additive manufacturing; CAE) and Design; Computer-Aided Engineering (CAD; Defects; Engineering; Heat exchangers; Industrial and Production Engineering; Lattice design; Lattices; Manufacturing defects; Measurement methods; Mechanical Engineering; Media Management; Original Article; Porosity; Post-processing; Powder beds; Process parameters; Rapid prototyping; Stiffness; Surface layers; Surgical implants; Manufacturing defects; Powder bed fusion; Lattice structures; Additive manufacturing
• ISSN: 0268-3768; 1433-3015
• DOI: 10.1007/s00170-019-04753-4

Additively manufactured lattice structures are popular due to their desirable properties, such as high specific stiffness and high surface area, and are being explored for several applications including aerospace components, heat exchangers and biomedical implants. The complexity of lattices challenges the fabrication limits of additive manufacturing processes and thus, lattices are particularly prone to manufacturing defects. This paper presents a review of defects in lattice structures produced by powder bed fusion processes. The review focuses on the effects of lattice design on dimensional inaccuracies, surface texture and porosity. The design constraints on lattice structures are also reviewed, as these can help to discourage defect formation. Appropriate process parameters, post-processing techniques and measurement methods are also discussed. The information presented in this paper contributes towards a deeper understanding of defects in lattice structures, aiming to improve the quality and performance of future designs.