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Design, Analysis, and Production of Lattice Structures Through Powder Bed Fusion Additive Manufacturing

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Materials, Structures and Manufacturing for Aircraft

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Abstract

Development of powder bed fusion additive manufacturing technologies enabled the introduction of novel components into various industries such as aerospace, biomedical, mold, and die. These novel components, which can be produced by powder bed fusion additive manufacturing, possess several advantages including internal features, lightweight structures, and integrated functionalities. Components with lattice structures are typical examples that possess most of the listed advantages. Lattice structures can be described as volumes or solids which mostly contain internal voids or spaces arrayed along with one or more directions in an orderly manner. They are categorized under three main groups as strut-based lattice structures, shell lattice structures, and triply periodic minimal surface lattice structures. Although their advantages are compelling for various industries, a sufficient understanding is essential to have the benefits. This chapter broadly presents the types and characteristics of lattice structures together with used analytical techniques. Furthermore, it explains different approaches for the design and analysis of these, considering the topology optimizations and the software used. Additionally, discussions on powder bed fusion additive manufacturing of lattice structures are included in the chapter with different aspects of the technique including but not limited to process parameters and process boundaries. All the provided information is supported with application examples from various industries.

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Abbreviations

2D:

Two-dimensional

3D:

Three-dimensional

AM:

Additive manufacturing

BCC:

Body-centered cubic

BCCZ:

Body-centered cubic-reinforced along Z-axis

CAD:

Computer-aided design

DC:

Diamond cubic

FCC:

Face-centered cubic

FCCZ:

Face-centered cubic along Z-axis

FEA:

Finite element analysis

FEM:

Finite element method

OT:

Octet Truss

PBF:

Powder bed fusion

SC:

Simple cubic

TPMS:

Triply periodic minimal surface lattice structures

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Acknowledgments

The authors would like to acknowledge that this literature survey was carried out in the scope of a project with a number of 120 N943 funded by the TUBITAK 2523 Program. One of the authors, Dr. Evren Yasa, would like to acknowledge that the SEM images given in Fig. 14.5 in this study are a result of research carried out under the TUBITAK ARDEB 1002 Program with a project number of 119 M781. She would also like to thank SLM Solutions GmbH for their assistance in the production of lattice structures.

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Authors and Affiliations

  1. Department of Mechanical Engineering, Eskişehir Technical University, Eskişehir, Turkey

    Ozgur Poyraz

  2. Department of Mechanical Engineering, Eskişehir Osmangazi University, Eskişehir, Turkey

    Evren Yasa

  3. Department of Bioengineering, Hacettepe University Institute of Science and Technology, Ankara, Turkey

    Fatma Nur Depboylu

  4. Faculty of Medicine, Department of Sports Medicine, Hacettepe University, Ankara, Turkey

    Feza Korkusuz

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  1. Ozgur Poyraz
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  2. Evren Yasa
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  4. Feza Korkusuz
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Correspondence to Ozgur Poyraz .

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Editors and Affiliations

  1. Aeronautical Engineering, Eskişehir Osmangazi University, Eskişehir, Turkey

    Melih Cemal Kuşhan

  2. Aeronautical Engineering, Eskişehir Osmangazi University, Eskişehir, Turkey

    Selim Gürgen

  3. Mechanical Engineering, Eskişehir Osmangazi University, Eskişehir, Turkey

    Mehmet Alper Sofuoğlu

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Poyraz, O., Yasa, E., Depboylu, F.N., Korkusuz, F. (2022). Design, Analysis, and Production of Lattice Structures Through Powder Bed Fusion Additive Manufacturing. In: Kuşhan, M.C., Gürgen, S., Sofuoğlu, M.A. (eds) Materials, Structures and Manufacturing for Aircraft. Sustainable Aviation. Springer, Cham. https://doi.org/10.1007/978-3-030-91873-6_14

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