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3D Printed Lattice Structures: A Brief Review

Conference Paper · November 2020

DOI: 10.1109/NAP51477.2020.9309680

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IEEE International Conference on “Nanomaterials: Applications & Properties” (NAP-2020)
Symposium on Additive Manufacturing and Applications (SAMA-2020)
Sumy, Ukraine, 9-13 Nov. 2020

3D Printed Lattice Structures: A Brief Review

Ande Harshavardhan Reddy Saritha Davuluri Dhatreyi Boyina
Department of Mechanical Engineering Department of Chemistry Department of Mechanical Engineering
Malla Reddy Engineering College (A) Chaitanya Bharathi Institute of Malla Reddy Engineering College (A)
Secunderabad, India Technology (A) Secunderabad, India
reddyh00@gmail.com Hyderabad, India dhatreyi@gmail.com
dsaritha_chm@cbit.ac.in

Abstract—Lattice structures are brilliant aspirants for
light-weight and energy absorbing usages similar to personal
shielding apparatus. The assembly of lattice structure is
promptly accomplished via 3D printing apparatus to fabricate
a product with low weight and amazing mechanical assets such
as good-strength and high-energy absorption. In this paper,
numerous vital features of lattice design and fabrication by
3Dprinting methods and their application for different
materials are discussed.
Keywords—3D printing, lattice structures, additive
manufacturing
I. INTRODUCTION
Lattice structures have numerous intrinsic benefits such
as lightweight, superior specific strength, rigidity. Lattices
are extensively explored for making lightweight panels,
cylinders and beams in aerospace engineering [1–3]. Lattice
structures with hierarchical configuration are capable of
bearing load. Lattice structures with exclusive low weight
and superior strength have been meritoriously utilized in
building sectors. Standard lattice framework is fabricated
with a huge quantity of uniform elements [4]. Mechanical
assets of Lattice structures have been explored for their
unique properties such as lightweight character, good
specific stiffness, strength and admirable performance [5-6].
Lattice systems with faults, deficiencies are rich in
surroundings [7]. The disorders in lattice systems
significantly affect their mechanical properties such as
elastic and fracture properties [8]. They take part in a
momentous task in attaining fuel effectiveness for the
aerospace and automotive productions [9]. Lightweight
materials such as Honeycombs, foams, and truss lattice
structures are explored due to their numerous applications
[10].
A lattice structure made up of repeat structural
constituents is known as cellular structure or unit cell
structure. Ordered and stochastic are the diverse cellular
arrangements. Stochastic lattices are made-up of
asymmetrical, arbitrary shaped cells of open or closed type.
Ordered lattices are formed by arranging identical 2D or 3D
cells in a periodic manner [11]. Adjacent cells share the
common wall also known as strut, and struts of different
cells merge at nodes. The inner profile of these lattice
structures can be in different geometric shapes depending
upon the application [12]. Lattice structures of various cell
geometries and strut shapes have been employed in medical,
material science and engineering applications [13-15].
Modern additive manufacturing technologies include
laser based methods like Metal Laser Sintering and
Selective Laser Melting to manufacture lattice structures
with required properties. By using these manufacturing
techniques and CAD software, different 3D lattice core
structures are produced [16].
Design and development of the products with less
substance utilization, trouble-free modern procedures, and
low energy expenditure are more essential for engineering
and industrial applications. Natural resources are exploited
for sustainable utilization of material and energy. Nature
designs numerous cellular structures because of its porous
and low volume fraction properties. Honeycomb, foam,
trabecular bone, and wood are the few of the examples of
cellular structures. Bone has a cellular structure and similar
strength as cast iron with light weight which can used in
engineering applications. If identical stresses are applied on
bone, it can able to form approximately equiaxed cells. Cork
is interesting natural cellular structure with outstanding
physical properties with light weight [1]. Production of
cellular structure-based design is difficult to manufacture
via traditional procedures. But, the fabrication of lattice with
difficult geometry can be developed via additive
manufacturing techniques proficiently and rapidly [17].
Redesign of Additive manufacturing constituent can be
attained with lightweight cellular structures or lattices [18-
19]. The benefits associated with the lattice structures is
effortless to realize in CAD model, ability to take up huge
quantity of deformation energy as desired, which can be
utilized in packing materials and personal protective
equipment. The progress of 3D printing expertise is hopeful
for the fabrication of metallic and non-metallic materials
with Low cost, competent production, Light weight, fine
mechanical properties [20]. The lattice structures, made-up
of different materials and they have various applications
compared to conventional materials due to their porous
mature. 3D printing processes are effective in producing
lattice structures of desired porosity [21]. Even the complex
geometries are easily produced with the 3D printing
methods [22]. Fused Deposition Modeling (FDM) ,
Selective Laser Sintering (SLS) and Stereo Lithography
(SLA) are the well-recognized 3D printing methods [23-25].
Due to high geometric complexity, conventional CAD
model optimization procedures are not enough for designing
the cellular-based lattice structures. Finite element analysis
method is employed for the better design and analysis of
these structures (Fig. 1) [26]. This paper targets to deliver a
review on the various metal and non-metal lattice structures
and their mechanical properties, 3D printing technologies as
well as the engineering applications.

978-1-7281-8506-4/20/$31.00 ©2020 IEEE 02SAMA10-1

 IEEE International Conference on “Nanomaterials: Applications & Properties” (NAP-2020)

extruded from a small nozzle according to 3D CAD models.

Fig. 1. Strength vs. density chart for engineering materials. There is a gap
in the low density high strength region which could be filled by lattice
structures [26].
II. 3D PRINTING METHODS
3D Printing technology is employed to change 3D
Computer-Aided Design (CAD) records into physical
prototype. 3D printing proto type was fabricated by slicing a
CAD model into a 2D layers and making them layer by
layer. Different 3D printing techniques are explored for
printing lattice structures of different materials. In this
review, Fused deposition modeling, Selective laser melting,
Stereolithography technologies are discussed. The selection
of printing method depends on the application which in turn
depends upon the material and preferred properties as listed
in Table I.
A. Fused Deposition Modeling (FDM)
Fusion deposition method is founded on thermal energy,
surface chemistry, and layer engineering skill. The filaments
of thermoplastic which are heated up to semi liquid state
TABLE I. PREDICTIONS, PROCESSING, AND APPLICATIONS OF DIFFERENT LATTICE STRUCTURES
The precise extrusion deposits as thin beads to produce the
first layer on the platform and this platform is kept at a little
temperature [27]. As a result, thermoplastic solidifies
rapidly. Subsequently, the base is moved down to deposit
another layer over the previous layer. This practice is
continued until the preferred pattern in quantified magnitude
is generated [28]. In FDM, filaments of diameter range 1.75
mm or 3.0 mm are generally employed. Fusion deposition
process is able to produce complex shapes without financing
in dies and molds and this method also permits the decrease
of the quantity of assemblies by making combined complex
parts [29]. Honeycomb and BCC lattice structures printed
using FDM are shown in Figs. 2(a) and 2(b).
B. Selective Laser Melting (SLM)
The Selective Laser Sintering procedure has the
capability to fix the material into a compact three
dimensional part. 3D printing process sinters the material
and incorporates the crystal structure and porosity in the
model. SLM printed gyroid structure is shown in the Fig.
2(c). The procedure was revealed to minimize a lot of
laborious manufacturing steps, since obtained product needs
only nominal cutting and thermo mechanical procedures.
Fabrication of alloys is the more recognized method using
this procedure to attain high micro hardness [30].
C. Stereolithography (SLA)
Stereolithography method utilized high-resolution
projection. The key benefits of this technique are tailorable
properties accompanied with great printing resolution.
Stereolithography is extensively employed technology based
on photo cuing of hydro-gel in layers. Computer operated
UV-laser light is glanced over the liquefied hydrogel surface
in a container which allows the formation of the covalent
bonds among the adjacent photo curable polymer chains. As
a result, 2D pattern with single layer is formed. The above
process is periodic till the 3D article is produced. Decent
quality surface textures, superior structural resolution are the
main benefits associated with this method [31-32]. SLA
printed stochastic lattice is presented in Fig. 2(d).

Process Material Application Lattice type Mechanical properties

Compression test: Failure and energy
Honeycomb [33]. BCC [34],
absorption [33,35], damage [34], elastic
FDM Thermoplastics Aerospace and medical [35] straight column [35], disordered
modulus [35]
[36]
Fracture test: fracture strength [36]
Photosensitive Compression test: Critical load [37]
thermosetting resins Stochastic[37] and honey
SLA Automobile [37] and dental [25] Hardness test: Hardness and fracture
Ceramics, comb[25]
Composites toughness [25]
Photovoltatic, biomedicine, Gyroid, diamond and primitive Compression Test: Relative elastic
SLS1 Thermoplastics
electrochromic [38] lattice structures [38] moduli, and collapse strengths [38]
Energy absorbing [39],
applications and scaffolds [13] Compression Test:
Gyroid, diamond, trabecular,
SLM/EBM2 Metals Biomedical implants [40-42], Energy absorption [39] , strength and
randomized [39-44]
Musical instruments [43], stiffness [13]
Prosthesis [44]
3D Kagome lattice, hexagonal
Inflatable wing design for small Compression Test:
Ink-jet Photopolymers diamond, and cross pyramidal
and deployable UAVs [45] Stress-strain behaviour [45]
structures [45]
Panels, beams, cylinders in Compression test:
LOM3 Plastics Hierarchical isogrid [46]
aerospace engineering [46] Bending and buckling behaviour [46]
1
SLS: Selective Laser Sintering
2
EMB: Electron Beam Melting
3
LOM: Laminated Object Manufacturing

02SAMA10-2
 IEEE International Conference on “Nanomaterials: Applications & Properties” (NAP-2020)
Fig. 2. Process – Lattice Structure type: a) FDM- Honeycomb [33], b) BCC
[34] c) SLM - Gyroid [13] and d) SLA- Stochastic [37].
III. MECHANICAL PROPERTIES
Lattice topology, cell geometry, 3D printing techniques
and processing factors affect the 3D printed lattice
structure’s behaviour significantly. This study offers the
impact of cell geometry, on the performance of lattice core
structures subjected to external loads. Based on cell
geometry, the lattice can be stochastic or non-stochastic.
Stochastic structures contain cells of non-repetitive
geometry. In these structures, porosity of the lattice structure
is considered as the main factor for predicting its mechanical
behaviour as the degree of randomness in cell geometry and
its arrangement is very high. Increase in the degree of
disorder in the cell arrangement leads to decrease in strength,
stiffness and energy absorption capacity [36]. It was inferred
that, lower the porosity, higher the energy absorption
capability of the structure [37].
Non-stochastic lattice structures consist of repetitive cell
geometries of auxetic or non-auxetic in nature. Honeycomb
and truss are the widespread non-auxetic core structures. The
truss shaped lattice core is proven to be highly stable, hence
its exhibits high bending strength and stiffness [47]. Under
compressive loading for Octet-truss lattice, the energy
absorbing capacity was found to be directly proportional to
the relative density [48]. The truss core has also exhibited
good local and global buckling behaviour by modifying its
ribs to T shape [46]. The stiffness and energy absorbing
properties of the honeycomb cell are enhanced by replacing
its cell wall triangular shaped lattice [49]. The auxetic core
structure, re-entrant-honeycomb has good energy absorption
under bending load [47] and also showed better sustainability
and durability under low impact loads [50].
IV. APPLICATIONS
High-strength light-weight materials have comparatively
superior stiffness and strength at low density and show a
momentous role in realizing fuel efficiency goals for the
aerospace and automotive industries [3] Honeycombs,
foams, and truss lattice structures belong to high-strength
light-weight materials. These lattice structures have widely
advanced and boosted to offer exceptional performance in
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numerous applications [7]. An open structure is the benefit
of truss lattices for heat transfer roles application.
Unmanned Aerial Vehicles (UAV) have established to
accomplish innumerable Army and civilian applications.
Newly, these vehicles have paid interest owing to promising
applications with elegant actions and amplified flexibilities
for minor transport attachments and storage. Elastic
performance of 3D Kagomes, 3D pyramidal and the
hexagonal diamond structures are high as confirmed by
compressive strength. So these structures are vastly suitable
in deployable UAV wing design [45].
The strategy and fabrication of lattice structures are
motivated due to their outstanding properties such as
lightweight nature, construct interval, consume energy, and
superior performance, extraordinary stiffness/ weight ratio,
brilliant energy absorption features, small heat conductivity,
momentous acoustic and thermal insulation properties
[25,51-53]. As a result, these structures can be explored in
several novel areas in aerospace, automotive, biomedical
and engineering industries [54]. Light and strong materials
are required for the aerospace industries which improve the
effectiveness of aircraft. Scientists have explored lattice core
structures to decrease the self-weight of constituents that
resemble the aerospace structures [55]. Materials with
excellent-strength and light-weight characteristics have
comparatively superior stiffness and excellent strength and
are attainable at low density. These materials exhibit a
momentous part in recognizing fuel effectiveness objective
of the automobile and aerospace structures [55]. Foams,
honeycomb cells, and truss shaped lattice core structures are
instances of the excellent-strength core with less-weight.
The lattice core structures are widely established and are
enriched with outstanding performance benefits in numerous
applications. Lattice core structures are suitable to fabricate
using wide variety of gels, ceramics, plastics and metals and
their alloys. Lattice structures are also applicable in
orthopedic implants. The tailorable porosity and stiffness of
these structures permit these to act as scaffolds in many bio-
implants like bones and tissues. These scaffolds, minimize
the difficulty in guarding the solid implants [56].
V. FUTURE PROSPECTS
Lattice structures are to be explored completely with
probable features of the design and applications in
aerospace, automobile and biomedical disciplines.
Distinctive structures need to be designed for a particular
application. Rigorous investigation need to be conducted to
determine the influence of processing parameters on the
mechanical behaviour of lattice structures. Robust design
packages and optimization tools are to be developed. Precise
Additive Manufacturing technologies need to be explored
for reducing the anisotropy and increasing the mass
production of these lattice structures.
VI. CONCLUSIONS
This paper has reviewed materials, manufacturing
techniques and applications of various lattice structures.
Most commonly these structures have been subjected to
compressive loading in order to predict the characteristics
like: energy absorption, stiffness and strength. These 3D
printed lattice core structures have potential applications in
various engineering and biomedical fields. Lattice structures
with brilliant mechanical properties manufactured from 3D
printing methods are gaining attention due to their enormous
functional benefits.
 IEEE International Conference on “Nanomaterials: Applications & Properties” (NAP-2020)
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