Work

Effect of 3D grading thickness on mechanical and deformation behaviour of gyroid structures produced via powder bed fusion with electron beam

Year: 2025

Type: article

Abstract: The production of complex geometries with geometrical tuned features is made possible by Additive manufacturing (AM) processes. Powder Bed Fusion using Electron Beam (PBF-EB) is one of the AM techniques for metallic components, which stands out for its ability to fabricate intricate structures with high-performance materials. One example is surface-based architectures known as Triply Periodic Minimal Surfaces (TPMS), where structural walls are defined by a specific thickness. The mechanical behaviour and deformation mechanisms of TPMS are governed by both the geometry and the wall thickness of the structure. Conventional TPMS designs typically employ a uniform or one-dimensional thickness gradient, which constrains their performance under varied loading conditions. This study explores a novel approach involving three-dimensional thickness gradation, aiming to enhance structural integrity, improve load-bearing capacity, and enable functional optimisation. The gyroid surface, a widely studied TPMS for applications ranging from lightweight aerospace components to biomedical implants, is used as a reference geometry. Three types of initiator surface (diagonal plane, cross-shape, and sphere) are employed to create spatial variations in wall thickness between predefined minimum and maximum values. Samples are fabricated using the PBF-EB process, and the resulting structures are characterised via X-ray computed tomography to assess morphometric parameters. These parameters are then correlated with mechanical properties and deformation mechanisms and compared against gyroid TPMS with uniform thickness. The results reveal a significant influence of 3D thickness variation on performance, offering new insights for the design and additive manufacturing of next-generation TPMS structures with tailored mechanical responses.

Source: Progress in Additive Manufacturing

DOI: 10.1007/s40964-025-01388-8

Authors: Danilo Bruson, Giovanni Rizza, Manuela Galati

Institution: Politecnico di Torino

Language: English

Topic: Cellular and Composite Structures

Subfield: Mechanical Engineering

Field: Engineering

Domain: Physical Sciences

SDG: Industry, innovation and infrastructure

Open Access status: hybrid

Estimated APC paid: $3,590