Towards implementing lattice structures into load-bearing lightweight components

This work explores the challenges met by the implementation of lattice structures into bulk parts from both design and manufacturing points of view. In the first part of this work, concepts for load introduction designs avoiding local stress concentration at both lattice-to-bulk and lattice-to-lattice interfaces are developed and numerically verified. In the second part of this work, the reliable additive manufacturing of sub-millimetre lattice structures in the framework of laser powder-bed fusion and manufacturing approaches for their implementation into bulk parts are investigated. Insights into the influence of manufacturing on the structural integrity of lattice structures and their inherent mechanical properties are provided in the frame of experimental validations as well. The present work proposes a framework for both standardised design and reliable manufacturing of test specimens for the mechanical characterisation of lattice structures under tensile loading. Furthermore, this contribution can be considered as a first milestone towards straightforward design guidelines on the implementation of lattice structures in lightweight components for daily engineering practice since the developed concepts are not specific and therefore not restricted to the employed AlSi10Mg powder material.