The Effect of Number and Size of Cellular Structures on Compressive Properties, Deformation Behavior, and Energy Absorption Characteristics of Ti6Al4V Lattice Structures Fabricated by Selective Laser Melting

This study explores how cellular numbers and sizes affect compressive properties and energy absorption of Ti6Al4V lattices manufactured via selective laser melting (SLM). Topology‐optimized cubic lattices with controlled porosity are designed using varying cell numbers (Z 1 , Z 8 , Z 27 , Z 64) and sizes (B 2 , B 4 , B 6 ). SLM‐fabricated specimens demonstrate improved strut accuracy with larger cellular sizes. Compression tests, digital image correlation, and finite element analysis reveal that increasing cellular numbers linearly enhances yield strength (37‐64 MPa) and elastic modulus (820‐1580 MPa), attributed to enhanced nodal connectivity and stress redistribution via “node weight theory.” Smaller cellular (2 mm) exhibits lower mechanical performance due to thin struts prone to shear failure, while larger cellulars (4‐6 mm) show superior strength and dimensional fidelity. Energy absorption capacity positively correlates with both cell quantity and size, though absorption efficiency increases with cell numbers but decreases with cell enlargement. The work identifies critical interactions between cellular numbers, sizes, and strut geometry under fixed‐volume constraints, demonstrating that nodal connectivity optimization outweighs strut thickness effects in mechanical enhancement. These findings provide a framework for designing porous biomedical implants with balanced compressive strength and energy absorption, while advancing predictive models for lattice structure performance.