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<p>Additive manufacturing of strut-based lattice structures offers a promising solution for bone defect restoration, providing a superior alternative to conventional implants in complex tissue engineering. This study evaluates the fatigue life of dumbbell lattice structures with varying nodal diameters (1.0&#xa0;mm, 1.1&#xa0;mm, and 1.2&#xa0;mm) while maintaining a consistent unit cell size. Very high-cycle fatigue testing (up to 10⁷ cycles) revealed improved fatigue strengths of 74&#xa0;MPa, 78&#xa0;MPa, and 82&#xa0;MPa for the respective configurations. Fatigue cracks primarily nucleated at the surface due to adhered powder despite minimal surface roughness. Failures were characterized by localized strain accumulation, forming a crush band at a 45° angle. Finite Element Analysis (FEA) in Abaqus validated experimental findings, and FE-SAFE simulations provided detailed fatigue life assessments, confirming enhanced fatigue performance. The results highlight the critical role of nodal reinforcement in optimizing lattice structures for biomedical applications.</p> Graphical Abstract <p>Enhanced fatigue performance of dumbbell-reinforced lattice structures due to improved nodal design and reduced stress concentrations.</p> <p></p>

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High-cycle fatigue analysis in dumbbell-shaped lattice structure of Ti6Al4V through additive manufacturing: experimental and numerical simulation

  • 期刊论文

  • 发表日期：

    2025年6月13日

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  • P. Parameswaran,
  • D. Kesavan,
  • R. Jayaganthan

摘要

Additive manufacturing of strut-based lattice structures offers a promising solution for bone defect restoration, providing a superior alternative to conventional implants in complex tissue engineering. This study evaluates the fatigue life of dumbbell lattice structures with varying nodal diameters (1.0 mm, 1.1 mm, and 1.2 mm) while maintaining a consistent unit cell size. Very high-cycle fatigue testing (up to 10⁷ cycles) revealed improved fatigue strengths of 74 MPa, 78 MPa, and 82 MPa for the respective configurations. Fatigue cracks primarily nucleated at the surface due to adhered powder despite minimal surface roughness. Failures were characterized by localized strain accumulation, forming a crush band at a 45° angle. Finite Element Analysis (FEA) in Abaqus validated experimental findings, and FE-SAFE simulations provided detailed fatigue life assessments, confirming enhanced fatigue performance. The results highlight the critical role of nodal reinforcement in optimizing lattice structures for biomedical applications.

Graphical Abstract

Enhanced fatigue performance of dumbbell-reinforced lattice structures due to improved nodal design and reduced stress concentrations.