Finite element modelling of defects in additively manufactured strut-based lattice structures

Strut-based lattice structures produced by powder bed fusion are prone to characteristic manufacturing defects that alter both their form and surface texture. Most studies in the literature focus on a subset of commonly observed defects, typically radius variation strut waviness; remain relatively unexplored. Furthermore, there remains need for development general finite element modelling framework can implement range into any strut-based design. This paper presents implementing meshes lattices. A signed distance function forms foundation this framework, upon which be modified converted tetrahedral via open-source software. The demonstrates how variation, waviness, elliptical cross sections modelled struts, intuitive mathematical definitions provided. parametric study is performed assess sensitivity compressive Young’s modulus BCCZ octet-truss lattices upskin downskin defects. results showed higher than BCCZ; designs were more sensitive