Manufacturability Analysis of Strut Lattice Design Using PLA-based Composite Material

Authors

  • Aini Zuhra Abdul Kadir School of Mechanical Engineering, Faculty of Engineering, Universiti Teknologi Malaysia, 81300, Johor Bahru, Johor, Malaysia
  • Siti Nur Humaira Mazlan School of Mechanical Engineering, Faculty of Engineering, Universiti Teknologi Malaysia, 81300, Johor Bahru, Johor, Malaysia
  • Rozlina Md Sirat School of Mechanical Engineering, Faculty of Engineering, Universiti Teknologi Malaysia, 81300, Johor Bahru, Johor, Malaysia
  • Rozaimi Mohd Saad School of Mechanical Engineering, Faculty of Engineering, Universiti Teknologi Malaysia, 81300, Johor Bahru, Johor, Malaysia
  • Zulkepli Muhamad School of Mechanical Engineering, Faculty of Engineering, Universiti Teknologi Malaysia, 81300, Johor Bahru, Johor, Malaysia

Keywords:

3D Printing, FDM, Lattice printing, CF-PLA, Wood-PLA

Abstract

Additive Manufacturing (AM) revolutionizes conventional manufacturing in the aspect of design complexities. Currently, 3D printing lattice structure is gaining attention due to its lightweight properties. Unfortunately, studies on the characterization and mechanical properties of AM composite lattice are still limited due to the insufficient availability of design rules for the lattice-development. Therefore, this study aims to perform a manufacturability analysis of strut-lattice design, in assisting the development of design rules for Fused Deposition Modelling (FDM) technique. Four types of strut-lattice consisted of square, circle, triangle, and octagon strut were designed and fabricated using carbon fibre PLA (CF-PLA) and Wood-PLA. The fabricated strut-lattice was inspected, evaluated, and compared with Virgin PLA based on the pass and fail criteria. The result showed that all of the composite and Virgin PLA parts were successfully fabricated when the strut sizes higher than 2.00 mm. It is anticipated that this study provides a guide to develop a set of new design rules focusing on lightweight structures and bring inspiration to the development of a range of lightweight-high strength mechanical applications.

References

Y. Tang and Y. F. Zhao, “A survey of the design methods for additive manufacturing to improve functional performance,” Rapid Prototyp. J., vol. 22, no. 3, pp. 569–590, 2016, doi: 10.1108/RPJ-01-2015-0011.

J. Zhu, H. Zhou, C. Wang, L. Zhou, and S. Yuan, “A review of topology optimization for additive manufacturing : Status and challenges,” Chinese J. Aeronaut., vol. 34, no. 1, pp. 91–110, 2021, doi: 10.1016/j.cja.2020.09.020.

M. Helou and S. Kara, “Design, analysis and manufacturing of lattice structures: An overview,” Int. J. Comput. Integr. Manuf., vol. 31, no. 3, pp. 243–261, 2018, doi: 10.1080/0951192X.2017.1407456.

D. J. McGregor, S. Tawfick, and W. P. King, “Mechanical properties of hexagonal lattice structures fabricated using continuous liquid interface production additive manufacturing,” Addit. Manuf., vol. 25, no. November 2018, pp. 10–18, 2019, doi: 10.1016/j.addma.2018.11.002.

C. Beyer and D. Figueroa, “Design and Analysis of Lattice Structures for Additive Manufacturing,” J. Manuf. Sci. Eng. Trans. ASME, vol. 138, no. 12, pp. 1–15, 2016, doi: 10.1115/1.4033957.

S. Y. Choy, C. N. Sun, K. F. Leong, and J. Wei, “Compressive properties of Ti-6Al-4V lattice structures fabricated by selective laser melting: Design, orientation and density,” Addit. Manuf., vol. 16, pp. 213–224, 2017, doi: 10.1016/j.addma.2017.06.012.

O. Iyibilgin, C. Yigit, and M. C. Leu, “Experimental investigation of different cellular lattice structures manufactured by fused deposition modeling,” 24th Int. SFF Symp. - An Addit. Manuf. Conf. SFF 2013, pp. 895–907, 2013.

Y. Norouzi, S. Rahmati, and Y. Hojjat, “A novel lattice structure for SL investment casting patterns,” Rapid Prototyp. J., vol. 15, no. 4, pp. 255–263, 2009, doi: 10.1108/13552540910979776.

K. Sharp, D. Mungalov, and J. Brown, “Metallic Cellular Materials Produced by 3D Weaving,” Procedia Mater. Sci., vol. 4, no. 1994, pp. 15–20, 2014, doi: 10.1016/j.mspro.2014.07.581.

E. Tyflopoulos and M. Steinert, “A comparative study between traditional topology optimization and lattice optimization for additive manufacturing,” Mater. Des. Process. Commun., no. December, pp. 1–6, 2019, doi: 10.1002/mdp2.128.

M. Roy, P. Tran, T. Dickens, and A. Schrand, “Composite Reinforcement Architectures: A Review of Field-Assisted Additive Manufacturing for Polymers,” J. Compos. Sci., vol. 4, no. 1, p. 1, 2019, doi: 10.3390/jcs4010001.

Y. Regassa, H. G. Lemu, and B. Sirabizuh, “Trends of using polymer composite materials in additive manufacturing,” IOP Conf. Ser. Mater. Sci. Eng., vol. 659, no. 1, 2019, doi: 10.1088/1757-899X/659/1/012021.

D. J. Shiwarski, A. R. Hudson, and J. W. Tashman, “Emergence of Fresh 3D printing as a platform for advanced tissue biofabrication,” APL Bioeng., vol. 5, no. 010904, pp. 1–14, 2021, doi: 10.1063/5.0032777.

M. Gibson L and Ashby, Cellular Solids: Structure and properties, vol. 2. 1997.

O. Iyibilgin, C. Yigit, and M. C. Leu, “Experimental investigation of different cellular lattice structures manufactured by fused deposition modeling,” 24th Int. SFF Symp. - An Addit. Manuf. Conf. SFF 2013, no. January, pp. 895–907, 2013.

Z. D. Denzik, “Investigation of lattice structures and analysis of strut geometry.,” 2017.

G. Dong, G. Wijaya, Y. Tang, and Y. F. Zhao, “Optimizing process parameters of fused deposition modeling by Taguchi method for the fabrication of lattice structures,” Addit. Manuf., vol. 19, pp. 62–72, 2018, doi: 10.1016/j.addma.2017.11.004.

S. N. H. Mazlan, A. Zuhra, A. Kadir, N. Hasrul, and A. Ngadiman, “Optimization of Truss Collinear Lattice Fabricated using Fused Deposition Modeling Technique,” Int. J. Innov. Technol. Explor. Eng., vol. 9, no. 2, pp. 3133–3139, 2019, doi: 10.35940/ijitee.l3566.129219.

P. F. Egan, I. Bauer, K. Shea, and S. J. Ferguson, “Mechanics of Three-Dimensional Printed Lattices for Biomedical Devices,” J. Mech. Des. Trans. ASME, vol. 141, no. 3, pp. 1–12, 2019, doi: 10.1115/1.4042213.

D. Melancon, Z. S. Bagheri, R. B. Johnston, L. Liu, M. Tanzer, and D. Pasini, “Mechanical characterization of structurally porous biomaterials built via additive manufacturing: experiments, predictive models, and design maps for load-bearing bone replacement implants,” Acta Biomater., vol. 63, pp. 350–368, 2017, doi: 10.1016/j.actbio.2017.09.013.

I. B. Ishak, M. B. Moffett, and P. Larochelle, “An algorithm for generating 3D lattice structures suitable for printing on a multi-plane FDM printing platform,” Proc. ASME Des. Eng. Tech. Conf., vol. 2B-2018, pp. 3–10, 2018, doi: 10.1115/DETC201885459.

G. K. Maharjan, S. Z. Khan, S. H. Riza, and S. H. Masood, “Compressive Behaviour of 3D Printed Polymeric Gyroid Cellular Lattice Structure,” IOP Conf. Ser. Mater. Sci. Eng., vol. 455, no. 1, 2018, doi: 10.1088/1757-899X/455/1/012047.

J. Kessler, N. Balc, A. Gebhardt, and K. Abbas, “Basic design rules of unit cells for additive manufactured lattice structures,” in MATEC Web of Conferences, 2017, vol. 137, pp. 1–10, doi: 10.1051/matecconf/201713702005.

Downloads

Published

2021-12-27

How to Cite

Abdul Kadir, A. Z., Mazlan, S. N. H., Md Sirat, R., Mohd Saad, R., & Muhamad, Z. (2021). Manufacturability Analysis of Strut Lattice Design Using PLA-based Composite Material. Jurnal Mekanikal, 44(02), 46–61. Retrieved from https://jurnalmekanikal.utm.my/index.php/jurnalmekanikal/article/view/434

Issue

Vol 44 : December 2021

Section

Mechanical

License

Copyright of articles that appear in Jurnal Mekanikal belongs exclusively to Penerbit Universiti Teknologi Malaysia (Penerbit UTM Press). This copyright covers the rights to reproduce the article, including reprints, electronic reproductions or any other reproductions of similar nature.