Dimensional and mechanical assessment of gyroid lattices produced in aluminum by laser powder bed fusion

The study investigates the use of aluminum gyroid lattices for structural purposes, with a particular focus on feasibility, dimensional accuracy, and compressive load performance. Gyroid lattice samples were built using laser powder bed fusion technology with AlSi10Mg, utilizing 3 cell sizes of 6, 8, and 12 mm and a wall thickness of 0.5 mm. The compression performance of the samples was tested experimentally and compared to the results of finite element analysis. The study revealed differences in dimensional accuracy in different directions, which were attributed to the fabrication process. Moreover, dimensional accuracy decreased with decreasing cell size due to unintentional material accumulation in the downskin areas. All samples were slightly heavier than expected, with no clear trend for the different cell sizes. However, the samples exhibited high compressive strength and stiffness, indicating their potential use for load-bearing and energy dissipation applications.