Mechanical properties and energy absorption capability of a topology-optimized lattice structure manufactured via selective laser melting under axial and offset loading

Intricate lattice structures can be fabricated by the selective laser melting method, which decreases the production limitations effectively and significantly provides more design freedom. In the present work, additive manufacturing and topological optimization are integrated to develop a novel body- and edge-centered 12 vertices lattice structure with modified triangular prismatic strut pattern (MTP-lattice). Finite element models of MTP-lattice were first established in PAM-CRASH and then experimentally verified via compressive test. The validated finite element models were then employed to investigate the novel MTP-lattice’s energy absorption and mechanical behavior under axial and offset loading. The results show that topology-optimized MTP-lattice has a superior energy absorption performance compared with competing unit cells. Besides, its mechanical performance is greatly influenced by the strut pattern and shape parameters. Furthermore, the deformation evolution from the overall structure to the strut level during the entire compression process was analyzed. The observations illustrate that the MTP-lattice exhibits a steady deformation mode with optimal shape parameters, which appears to have a promising prospect for the application of crashworthy components. The research results provide excellent guidance for the application of novel lightweight energy-absorbing lattice.