One of the main benefits of 3D printing is the design freedom it allows for, and lattice structures are a prime example of this. These repeatable geometric mesh patterns can replace solid surfaces within a part to reduce weight, increase energy absorption, improve load distribution, and more. By becoming familiar with the advantages of lattice structures, their typical applications, and some of the common lattice cell designs, you can open up new possibilities that will help take your parts and products to the next level.
While lattice structures are difficult or impossible to machine or mold, they can easily be 3D printed using plastic or metal, and can be modified based on your part design and application. At 3D Parts Unlimited, we specialize in manufacturing high-quality, production-grade 3D printed parts, and can help guide you in all facets of 3D printing. From process and material selection to advice on design for additive manufacturing (DfAM), lattice structures, and cost optimization, 3D Parts Unlimited is equipped to be your go-to 3D printing partner.
Key Benefits of 3D Printed Lattice Structures
Before we explore the different types of lattice structures, it’s first important to understand why they may be beneficial to include in your part design.
Lightweighting
Particularly important within the aerospace industry, but also for performance automotive and robotics components, lightweighting is the practice of designing parts for reduced weight while maintaining their desired mechanical properties and functions. Lattice structures excel in applications where lightweighting is a concern, as they require less material, and are thus significantly lighter, than solid parts.
Increased Energy Absorption
With the design flexibility that 3D printing provides, engineers are able to create custom cell shapes and lattice designs that offer enhanced energy absorption. Due to their lightweight, airy designs, lattice structures demonstrate high specific energy absorption (SEA) — the amount of energy absorbed relative to mass — making them incredibly effective for applications like aerospace parts where shock resistance, strength, and weight are all critical factors.
Improved Load Distribution
By adjusting the thickness of the beams and the density of cells at different points within a part, lattice structures can be tuned to transfer force in a more controlled manner. This provides increased stability for parts that undergo changing loads or for applications where the force of sudden impacts needs to be directed away from sensitive components.
Reduced Cost
Using lattice structures can help you reduce the amount of material required to print your parts, resulting in both lower material costs and faster print times — that means shorter lead times, as well. A perfect example of this are the custom machine and test fixtures that 3D Parts Unlimited manufactured for Kohler, saving them $325.00 per fixture and reducing their lead time from two to three weeks to two days.
In addition to lowering production costs, 3D printing parts with lattice structures can often help save money in other ways. This is particularly true when manufacturing parts for spacecraft, where every ounce of weight adds thousands of dollars in fuel costs.
Common 3D Printed Lattice Structure Patterns
There are many different lattice structure cell patterns that can be incorporated into a part design, and the optimal choice largely depends on your application. While lattice structures are almost infinitely customizable, there are a few common cell shapes that you should be familiar with before designing your next part.
Cube
Cubes are one of the most basic lattice structure cell designs, and are principally used for lightweighting and reducing material usage while preserving the structural integrity of a part. Simple to design and cost-effective to manufacture, cube lattice structures are particularly well-suited for use in industrial applications, such as manufacturing fixtures and jigs,
Diamond/Triangle
Diamond and triangle lattice structure cell designs are very similar, each offering the benefits of increased load distribution uniformity and high stiffness. With these properties, diamond and triangle lattice structure patterns are ideal for applications where both strength and impact force distribution are critical, such as in aerospace components, impact-absorbant automotive components, and protective sporting goods equipment.
Honeycomb
The honeycomb lattice structure cell design is incredibly versatile, and is typically used to make parts that are both strong and lightweight. The mechanical properties of honeycomb lattices are ideal for aerospace applications, performance automotive parts, and medical devices like prosthetics. In addition, the visual appeal of the honeycomb pattern can make this design a great fit for consumer products.
Voronoi
Voronoi lattice structures are notable for their unique organic appearance, so it may not be surprising that this design is often used for applications within the medical industry. Specifically, Voronoi lattice structures are common when 3D printing components for biomimicry of bone structures and cellular growth patterns.
Discover How to Incorporate 3D Printed Lattice Structures Into Your Part Designs
Lattice structures may seem complex, but they can be easy to implement within your part design if you’re working with an experienced 3D printing partner. At 3D Parts Unlimited, we offer a wide variety of 3D printing technologies ideal for manufacturing parts with lattice structures, including:
- HP Multi Jet Fusion (MJF)
- Fused Deposition Modeling (FDM)
- Selective Laser Sintering (SLS)
- Stereolithography (SLA)
- Direct Light Printing (DLP)
- Direct Metal Laser Sintering (DMLS)
In addition to manufacturing, we can also help guide your engineering team on material and process selection, DfAM, proper use of lattice structures, and more.
Could your parts benefit from using lattice structures? Contact us today to discuss your part designs or request a quote and discover what 3D Parts Unlimited can do for you.