Voxel-based 3D reconstruction of additively manufactured open porous structures for CFD simulation

With the ability to manufacture complex functional structures, Additive Manufacturing (AM) enables new advanced applications which could not be realized before. An example of such structures is open porous structures. In the presented approach, the open porous structures are a result of the selected manufacturing parameters, instead of being defined in CAD models. Thereby, various porosities can be achieved flexibly without design adjustments. However, to comprehensively understand the correlation of manufacturing parameters and different properties, various tests are required. As an alternative, properties can be determined by means of simulation. This study presents 3D reconstructions of complex open porous structures, which are based on μ-CT imaging. The influence of the downsampling during voxelization on the 3D reconstructed geometry is studied. Further, different polyhedral mesh settings have been tested in order to find a mesh that minimizes the deviation between the CFD simulation results and the laboratory test results for flow resistance. A guideline for the creation of a calibrated CFD model based on μ-CT imaging is proposed. As it is acknowledged by the authors that the data availability to reconstruct shown cases is crucial, data for a reference case have been made freely available online.