Finite Element Analysis Approach for Optimal Design and Mechanical Performance Prediction of Additive Manufactured Sandwich Lattice Structures

Additive manufacturing (AM) has paved a path to many technological developments that were not possible with the traditional manufacturing techniques like the lattice structures. Lattice structures are gaining importance owing to their unique mechanical properties, better strength/weight ratios, and better energy absorption capabilities. Theoretically, the application of lattice structures will decrease the amount of material usage for production at the cost of resistance to stresses and overall rigidity. This study presents a comprehensive study of strut, honeycomb, and minimal surface-based designs for sandwich lattice structures, aiming to identify the optimal lattice configuration. The findings from this study hold practical importance for manufacturing applications across diverse industries, including but not limited to automobiles, marine, and biomedical fields. Utilizing finite element analysis (FEA) and stiffness matrix simulations, the mechanical behavior of sandwiched lattice unit cell structures was investigated. Results demonstrated good agreement with the existing literature on uniform lattice structures, validating the accuracy of the method in defining mechanical properties. Honeycomb structures exhibited superior stiffness, while minimal surface designs showcased lower stresses in compressive load simulations, indicating effective load distribution and potential higher yield strength. Minimal surfaces also exhibited advantages in fatigue life due to the absence of stress concentrated regions like corners and sharp edges. The Octet design also emerged as a promising option for structural performance.