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The compressive behaviour of ABS gyroid lattice structures manufactured by fused deposition modelling

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Abstract

Additive manufactured (AM) cellular structures have received much research attention due to their specific strength and energy absorption capabilities, and a range of geometric, material and processing parameters has been found to affect their manufacturability and mechanical performance. To investigate the effects of wall thickness and cell size on manufacturability and mechanical properties, gyroid lattice structures were fabricated from acrylonitrile butadiene styrene (ABS) using fused deposition modelling (FDM) and tested under quasi-static loading. Gyroids were confirmed to be highly manufacturable structures, and increasing density was found to further improve manufacturability. Mechanical behaviour was found to be dominated by the geometry and topology of the gyroids rather than manufacturing effects. Mechanical testing results were consistent with the predictions of the Gibson-Ashby model for cellular structures, and formulae were generated to predict the mechanical behaviour of ABS gyroid lattice structures produced by FDM. This work provides tools to enable a priori prediction of the mechanical behaviour of ABS gyroids manufactured by FDM and a greater understanding of opportunities and limitations of these structures.

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Notes

  1. Relative density is the ratio of density of the cellular structure (ρ*) to the density of the structure’s parent material (ρs).

  2. Specimen “3C050W” has three cells in each direction and a walk thickness of 0.5 mm.

Abbreviations

ABS:

Acrylonitrile butadiene styrene

AM:

Additive manufacture

CAD:

Computer-aided design

DFAM:

Design for additive manufacturing

EBM:

Electron beam melting

FDM:

Fused deposition modelling

GD:

Generative design

MEX:

Material extrusion

μCT:

Micro-computed tomography

PLA:

Polylactic acid

SLM:

Selective laser melting

SLS:

Selective laser sintering

STL:

Stereolithography file

TPMS:

Triply periodic minimal surface

C :

Number of cells

L :

Cell length of the cubic structure (mm)

W :

Wall thickness (mm)

P * :

Property of a cellular structure

P s :

Property of bulk material

E* :

Static modulus of a cellular structure

E s :

Static modulus of bulk material

σ * :

Strength of a cellular structure

σ s :

Strength of bulk material

σ y :

Specimen yield strengths

ρ ∗ :

Density of cellular structure

ρ s :

Density of solid bulk material

X Y Z :

Cartesian coordinates

ωx, ωy, ωz :

Cell frequencies in X, Y, Z

R 2 :

R-squared value indicating percentage of variance predicted by regression model

\( {R}_{\mathrm{adj}}^2 \) :

Adjusted R-squared value considering number of terms in regression model

\( {R}_{\mathrm{pred}}^2 \) :

Predicted R-squared value

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Acknowledgements

This research was conducted by the Australian Research Council Industrial Transformation Training Centre in Additive Biomanufacturing (IC160100026).

The authors acknowledge the facilities, and the scientific and technical assistance of the RMIT Advanced Manufacturing Precinct.

Funding

This research is funded by the members of the ARC Training Centre for Lightweight Automotive Structures and from the Australian Research Council (Grant Reference IC160100032).

Author information

Authors and Affiliations

  1. RMIT Centre for Additive Manufacture, RMIT University, Melbourne, Australia

    Tobias Maconachie, Rance Tino, Bill Lozanovski, Marcus Watson, Alistair Jones, Chrysoula Pandelidi, Ahmad Alghamdi, Abduladheem Almalki, David Downing, Milan Brandt & Martin Leary

  2. ARC Training Centre for Lightweight Automotive Structures (ATLAS), Australian Research Council Grant IC160100032, Melbourne, Australia

    Tobias Maconachie, Marcus Watson, Alistair Jones & Martin Leary

  3. ARC Training Centre in Additive Biomanufacturing, Brisbane, Australia

    Rance Tino, Bill Lozanovski & Martin Leary

Authors
  1. Tobias Maconachie
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  2. Rance Tino
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  3. Bill Lozanovski
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  10. Milan Brandt
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Correspondence to Tobias Maconachie.

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Mechanical properties of gyroid specimens

Mechanical properties of gyroid specimens

The mechanical properties of all tested specimens are presented in Table 14.

Table 14 Mechanical properties of tested gyroid specimens
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Maconachie, T., Tino, R., Lozanovski, B. et al. The compressive behaviour of ABS gyroid lattice structures manufactured by fused deposition modelling. Int J Adv Manuf Technol 107, 4449–4467 (2020). https://doi.org/10.1007/s00170-020-05239-4

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