Lattice structures have garnered extensive attention for their lightweight properties and high-energy absorption capacity. The inlaid lattice structure, comprising interconnected unit cells, enhances mechanical behavior through inlaying. AlSi10Mg powder served as the material, and FB/BF inlaid lattice structures incorporating body-centered cubic (BCC) and face-centered cubic (FCC) unit cells were fabricated via selective laser melting. Mechanical properties and fracture modes were subsequently analyzed. Results indicate that reducing strut diameter degrades the mechanical properties of FB and BF structures. The BF structure decreases to <68% of its original properties, while FB retains >86% when the BCC-strut diameter is reduced. FB exhibits superior mechanical properties, with maximum yield strengths of 112 MPa (FB) and 105 MPa (BF), exceeding those of uniform BCC structures at identical relative densities. Under compression, the structure fails initially through layer-by-layer fracture, then fractures at ∼45°, showing a mixed fracture mode characterized predominantly by ductile fracture with a minor contribution of brittle fracture.
SongG-H, JingS-K, ZhaoF-L, et al.Design optimization of irregular cellular structure for additive manufacturing. Chin J Mech Eng, 2017; 30(5):1184–1192; doi: 10.1007/s10033-017-0168-3
2.
MiaoX, HuJ, XuY, et al.Review on mechanical properties of metal lattice structures. Compos Struct, 2024; 342:118267; doi: 10.1016/j.compstruct.2024.118267
3.
KorkmazME, GuptaMK, RobakG, et al.Development of lattice structure with selective laser melting process: A state of the art on properties, future trends and challenges. J Manuf Process, 2022; 81:1040–1063; doi: 10.1016/j.jmapro.2022.07.051
4.
AzarniyaA, ColeraXG, MirzaaliMJ, et al.Additive manufacturing of Ti–6Al–4V parts through laser metal deposition (LMD): Process, microstructure, and mechanical properties. J Alloys Compd, 2019; 804:163–191; doi: 10.1016/j.jallcom.2019.04.255
5.
ZhangXZ, LearyM, TangHP, et al.Selective electron beam manufactured Ti-6Al-4V lattice structures for orthopedic implant applications: Current status and outstanding challenges. Current Opinion Solid State Materials Sci, 2018; 22(3):75–99; doi: 10.1016/j.cossms.2018.05.002
6.
LyLN, DucVM, TrungN-T, et al.An analytical approach to the nonlinear buckling behavior of axially compressed auxetic-core cylindrical shells with carbon nanotube-reinforced coatings. J Materials Design Appl, 2021; 235(10):2254–2265; doi: 10.1177/14644207211033320
7.
ZhangXY, RenX, ZhangY, et al.A novel auxetic metamaterial with enhanced mechanical properties and tunable auxeticity. Thin-Walled Struct, 2022; 174:109162; doi: 10.1016/j.tws.2022.109162
8.
FengL-J, XiongJ, YangL-H, et al.Shear and bending performance of new type enhanced lattice truss structures. Int J Mech Sci, 2017; 134:589–598; doi: 10.1016/j.ijmecsci.2017.10.045
9.
MonteiroJ, SardinhaM, AlvesF, et al.Evaluation of the effect of core lattice topology on the properties of sandwich panels produced by additive manufacturing. J Materials Design Appl, 2021; 235(6):1312–1324; doi: 10.1177/1464420720958015
10.
VlădulescuF, ConstantinescuDM. Lattice structure optimization and homogenization through finite element analyses. J Materials Design Appl, 2020; 234(12):1490–1502; doi: 10.1177/1464420720945744
11.
DaraA, Johnney MertensA, Raju BahubalendruniMVA. Characterization of penetrate and interpenetrate tessellated cellular lattice structures for energy absorption. J Materials Design Appl, 2023; 237(4):906–913; doi: 10.1177/14644207221129709
12.
DaraA, BahubalendruniMAR, Johnney MertensA, et al.Numerical and experimental investigations of novel nature inspired open lattice cellular structures for enhanced stiffness and specific energy absorption. Mater Today Commun, 2022; 31:103286; doi: 10.1016/j.mtcomm.2022.103286
13.
HelouM, KaraS. Design, analysis and manufacturing of lattice structures: An overview. Int J Comput Integr Manuf, 2018; 31(3):243–261; doi: 10.1080/0951192X.2017.1407456
14.
RenF, WangL, LiuH. Low frequency and broadband vibration attenuation of a novel lightweight bidirectional re-entrant lattice metamaterial. Mater Lett, 2021; 299:130133; doi: 10.1016/j.matlet.2021.130133
15.
AkçayFA, WuD, BaiY. Comprehensive studies on strength of 3D-printed aluminum micro lattice structures. Procedia Structural Integrity, 2020; 28:1399–1406; doi: 10.1016/j.prostr.2020.10.112
16.
WuJ, ZhangY, YangF, et al.A hybrid architectural metamaterial combing plate lattice and hollow-truss lattice with advanced mechanical performances. Addit Manuf, 2023; 76:103764; doi: 10.1016/j.addma.2023.103764
17.
MaskeryI, AboulkhairNT, AremuAO, et al.A mechanical property evaluation of graded density Al-Si10-Mg lattice structures manufactured by selective laser melting. Materials Science and Engineering: A, 2016; 670:264–274; doi: 10.1016/j.msea.2016.06.013
18.
LiL, YangF, WangP, et al.A new hybrid lattice structure with improved modulus, strength and energy absorption properties. Sci China Technol Sci, 2023; 66(7):2119–2133; doi: 10.1007/s11431-022-2199-5
DeshpandeVS, FleckNA, AshbyMF. Effective properties of the octet-truss lattice material. J Mech Phys Solids, 2001; 49(8):1747–1769; doi: 10.1016/S0022-5096(01)00010-2
21.
TimoshenkoSP, GereJM, PragerW. Theory of elastic stability, second edition. J Appl Mech, 1962; 29(1):220–221; doi: 10.1115/1.3636481
22.
Al-KetanO, RowshanR, Abu Al-RubRK. Topology-mechanical property relationship of 3D printed strut, skeletal, and sheet based periodic metallic cellular materials. Addit Manuf, 2018; 19:167–183; doi: 10.1016/j.addma.2017.12.006
23.
LiuH, GuD, QiJ, et al.Dimensional effect and mechanical performance of node-strengthened hybrid lattice structure fabricated by laser powder bed fusion. Virtual Phys Prototyp, 2023; 18(1):e2240306; doi: 10.1080/17452759.2023.2240306
24.
DingJ, MaQ, LiX, et al.Imperfection‐enabled strengthening of ultra‐lightweight lattice materials. Adv Sci, 2024; 11(41):2402727; doi: 10.1002/advs.202402727
25.
CheahCM, ChuaCK, LeeCW, et al.Rapid prototyping and tooling techniques: A review of applications for rapid investment casting. Int J Adv Manuf Technol, 2005; 25(3–4):308–320; doi: 10.1007/s00170-003-1840-6
26.
SharpK, MungalovD, BrownJ. Metallic cellular materials produced by 3D weaving. Procedia Mater Sci, 2014; 4:15–20; doi: 10.1016/j.mspro.2014.07.581
27.
JagadishRA. Cutting fluid selection for sustainable design for manufacturing: An integrated theory. Procedia Mater Sci, 2014; 6:450–459; doi: 10.1016/j.mspro.2014.07.058
28.
AriffZM, AfolabiLO, SalmazoLO, et al.Effectiveness of microwave processing approach and green blowing agents usage in foaming natural rubber. J Mater Res Technol, 2020; 9(5):9929–9940; doi: 10.1016/j.jmrt.2020.06.096
29.
AliM, SajjadU, HussainI, et al.On the assessment of the mechanical properties of additively manufactured lattice structures. Eng Anal Bound Elem, 2022; 142:93–116; doi: 10.1016/j.enganabound.2022.05.019
30.
ShuaiC, ZhongS, ShuaiY, et al.Accelerated anode and cathode reaction due to direct electron uptake and consumption by manganese dioxide and titanium dioxide composite cathode in degradation of iron composite. J Colloid Interface Sci, 2023; 632(Pt A):95–107; doi: 10.1016/j.jcis.2022.11.055
31.
ShuaiX, YangY, QiF, et al.Phase-field modeling of laser sintering degradable biopolymer. Compos Commun, 2025; 53:102244; doi: 10.1016/j.coco.2024.102244
32.
ShuaiX, YangL, QiF, et al.Theoretical analysis of self-shrinkage spheroidization of irregular degradable polymer powder under thermodynamic nonequilibrium state. Addit Manuf Front, 2024; 3(4):200173; doi: 10.1016/j.amf.2024.200173
33.
BabamiriBB, BarnesB, Soltani-TehraniA, et al.Designing additively manufactured lattice structures based on deformation mechanisms. Addit Manuf, 2021; 46:102143; doi: 10.1016/j.addma.2021.102143
34.
ChengL, BaiJ, ToAC. Functionally graded lattice structure topology optimization for the design of additive manufactured components with stress constraints. Comput Methods Appl Mech Eng, 2019; 344:334–359; doi: 10.1016/j.cma.2018.10.010
35.
VránaR, JarošJ, KoutnýD, et al.Contour laser strategy and its benefits for lattice structure manufacturing by selective laser melting technology. J Manuf Process, 2022; 74:640–657; doi: 10.1016/j.jmapro.2021.12.006
36.
RashidR, MasoodSH, RuanD, et al.Effect of energy per layer on the anisotropy of selective laser melted AlSi12 aluminium alloy. Addit Manuf, 2018; 22:426–439; doi: 10.1016/j.addma.2018.05.040
37.
ZhangY, AiyitiW, DuS, et al.Design and mechanical behaviours of a novel tantalum lattice structure fabricated by SLM. Virtual Phys Prototyp, 2023; 18(1):e2192702; doi: 10.1080/17452759.2023.2192702
38.
ZhongH, DASR, GuJ, et al.Low-density, high-strength metal mechanical metamaterials beyond the Gibson-Ashby model. Materials Today, 2023; 68:96–107; doi: 10.1016/j.mattod.2023.07.018
39.
CalladineCR. Buckminster Fuller’s “Tensegrity” structures and Clerk Maxwell’s rules for the construction of stiff frames. Int J Solids Struct, 1978; 14(2):161–172; doi: 10.1016/0020-7683(78)90052-5
40.
KingWE, AndersonAT, FerenczRM, et al.Laser powder bed fusion additive manufacturing of metals; physics, computational, and materials challenges. Appl Phys Rev, 2015; 2(4):e041304; doi: 10.1063/1.4937809
41.
LearyM, MazurM, ElambasserilJ, et al.Selective laser melting (SLM) of AlSi12Mg lattice structures. Mater Design, 2016; 98:344–357; doi: 10.1016/j.matdes.2016.02.127
