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Ventilated surface-based lattice structures designed for polymer powder bed fusion process

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Abstract

This work addresses the issues of entrapment of polymer powder and the post-processing powder removal challenges in surface-based lattice structures 3D printed with powder bed-based additive manufacturing (AM) technology. A ventilation design approach has been proposed to enhance the powder removability from the widely researched three-dimensional gyroid and two-dimensional honeycomb lattice structure. The flow characteristics and mechanical behavior of the designed lattices were analyzed using computational fluid dynamics (CFD) and finite element analysis (FEA), respectively, followed by experimental powder flow and compression testing. HP jet fusion 4200® industrial 3D printer was used for printing the lattice structures for experimental validation. The results showed a 65–85% improvement in powder flowability, with a minimum to severe reduction in mechanical strength of different lattice structures. The study can be applied to designing products with multi-functional properties with surface-based lattice structures by employing the principle of design for additive manufacturing and post-processing (DfAM&PP).

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Funding

This research work is financially supported by the Taiwan High Speed 3D Printing Research Center from the Featured Areas Research Center Program within the framework of the Higher Education Sprout Project by the Ministry of Education (MOE) (grant number 108PO15) in Taiwan.

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Authors and Affiliations

  1. Taiwan High Speed 3D Printing Research Center, National Taiwan University of Science and Technology, No. 43, Sec. 4, Keelung Rd, Taipei, 106, Taiwan, Republic of China

    Saurav Verma & Jeng-Ywan Jeng

  2. Department of Mechanical Engineering, National Taiwan University of Science and Technology, No. 43, Sec. 4, Keelung Rd, Taipei, 106, Taiwan, Republic of China

    Saurav Verma & Jeng-Ywan Jeng

  3. Design for Additive Manufacturing & Innovation (DAMI) Lab, Department of Design, Indian Institute of Technology Guwahati, Guwahati, 781039, Assam, India

    Ajeet Kumar

  4. Department of Design, Indian Institute of Technology Guwahati, Guwahati, 781039, Assam, India

    Jeng-Ywan Jeng

  5. Academy of Innovative Semiconductor and Sustainable Manufacturing, National Cheng Kung University, No. 1, Dasyue Rd, Tainan City, 701, Taiwan, Republic of China

    Jeng-Ywan Jeng

  6. Additive Manufacturing Journal, NTUST, Taipei, Taiwan

    Jeng-Ywan Jeng

Authors
  1. Saurav Verma
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  2. Ajeet Kumar
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  3. Jeng-Ywan Jeng
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Contributions

All authors contributed to the conception and design of this study. The material preparation, methodology, analysis, data collection, and writing the original draft were performed by Saurav Verma. The project administration, technical guidance, and investigation were performed by Ajeet Kumar. And the idea validation, project supervision, and funding acquisition were performed by Jeng Ywan Jeng. All authors have contributed in commenting and editing of the manuscript. All authors have read and approved the final manuscript.

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Correspondence to Jeng-Ywan Jeng.

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Verma, S., Kumar, A. & Jeng, JY. Ventilated surface-based lattice structures designed for polymer powder bed fusion process. Int J Adv Manuf Technol 132, 113–126 (2024). https://doi.org/10.1007/s00170-024-13304-5

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  • DOI: https://doi.org/10.1007/s00170-024-13304-5

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