Experimental and numerical mechanical characterisation of additively manufactured polymeric lattice structures under uniaxial tensile load

Additive manufacturing enables the production of lighter, more robust components with intricate features like lattice structures. However, since the mechanical behaviour of lattice structures is not fully characterized, the application of such potential is limited today. The challenge with lattice structures tensile tests is defining a suitable design that fits the standard requirements and process characteristics. In the polymeric powder bed fusion process, the problem is to produce powder-free geometries and to avoid stress concentrations zones, adapting the specimen accordingly. In this regard, numerical simulation may provide insightful information and support the analysis of the deformation mechanisms. This paper analyses a new tensile sample for lattice structures using finite element analysis. The sample is designed following the EN ISO 527 standard prescriptions. An area with a controlled gradation of the lattice relative density is designed to ensure both powder-free voids and fracture localization within the lattice specimen gauge length. Experimental tests are performed to validate the numerical results using a modified body cubic centred topology with two different strut diameters. The specimens are produced in polyamide by powder bed AM process. Due to the complexity of the lattice design, a digital image correlation is used to compute the full range of strains at the macroscopic level. Experimental and numerical strain maps results showed a good agreement. The recorded deviation was attributed to the process-induced defect, such as the geometrical accuracy that, if compensated, boosted the capability of the numerical model to predict the mechanical behaviour of the lattice structure.