Computational modelling of strut defects in SLM manufactured lattice structures

Lozanovski, B, Leary, M, Tran, J, Shidid, D, Ma, Q, Choong, P and Brandt, M 2019, 'Computational modelling of strut defects in SLM manufactured lattice structures', Materials & Design, vol. 171, pp. 1-18.

Document type: Journal Article
Collection: Journal Articles

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Title Computational modelling of strut defects in SLM manufactured lattice structures
Author(s) Lozanovski, B
Leary, M
Tran, J
Shidid, D
Ma, Q
Choong, P
Brandt, M
Year 2019
Journal name Materials & Design
Volume number 171
Start page 1
End page 18
Total pages 18
Publisher Elsevier
Abstract Addition of manufacturing defects to computational models of 3D-printed lattice structures enable improved simulation accuracy. A computational model of a cellular structure based on finite element method (FEM) analysis, often starts from defect-free computer-aided design (CAD) geometries to generate discretised meshes. Such idealised CAD geometries neglect imperfections, which occur during the additive manufacturing process of lattice structures, resulting in model oversimplification. This research aims to incorporate manufacturing defects in the strut elements of a lattice structure, thereby enhancing predictive capabilities of models. In this work, a method of generating CAD AM representative strut models is proposed. The models are generated from micro-computer tomography (μCT) analysis of SLM fabricated struts. The proposed additive manufacturing (AM) representative strut FE model's axial stiffness and critical buckling load is compared to idealised- and μCT- based FE models, with significant error reduction over idealised strut models. The AM representative strut models are then used to generate full lattice FE models and compared with manufactured and idealised FE models. The AM representative FE lattice models show greater correlations toward experiment and more realistic deformation behaviours. Overall, the methodology used in this study demonstrates a novel approach to representing struts in FE models of AM fabricated lattice structures.
Subject Numerical Modelling and Mechanical Characterisation
Keyword(s) Selective laser melting (SLM)
Lattice structures
Finite element analysis (FEA)
Computer-aided design (CAD)
Defect modelling
DOI - identifier 10.1016/j.matdes.2019.107671
Copyright notice © 2019 Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license (
ISSN 0264-1275
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