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<p>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.</p>

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

  • 期刊论文

  • 出版模式：

    开放获取

  • 发表日期：

    2025年10月17日

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  • Danilo Bruson,
  • Giovanni Rizza,
  • Manuela Galati

摘要

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.