Impact of unit cell size on the compressive behavior of L-PBF fabricated maraging steel gyroid lattices

This study investigates the compressive performance of maraging steel gyroid lattice structures fabricated via Laser Powder Bed Fusion ( L -PBF). Gyroid lattices with varying unit cell sizes were designed and additively manufactured under ideal process parameters. Quasi-static compression tests revealed a significant influence of unit cell size on the structural response, with smaller cell sizes exhibiting higher strength and energy absorption due to improved load distribution efficiency. The lattice with a unit cell size of 5 mm demonstrated the highest quasi-elastic Gradient of 2.3 GPa and a compressive strength of 83 MPa at a relative density of 0.25. Scanning Electron Microscopic analysis revealed that the lattice with a larger unit cell size exhibited minor strut fractures, which resulted in lower energy absorption. These findings provide valuable insights for optimizing lattice geometries in load-bearing structures, energy absorbers, and lightweight lattice cores for aerospace applications using additive manufacturing.