Additive Manufacturing of Graded TPMS and Voronoi Lattices in AlSi10Mg: From Design to Mechanical Characterization

Applications of Machine Learning AlLaser Powder Bed Fusion (LPBF), a type of additive manufacturing, allows for the production of metallic lattice structures with highly adaptable geometries and graded material properties. Functionally Graded Lattice Structures (FGLS) are advantageous for high-performance applications, including biomedical implants. These advanced structures, produced through additive manufacturing (AM), exhibit spatially varying mechanical properties that are crucial for mimicking biological gradients, thereby reducing stress shielding and promoting better integration. This thesis explores the design, fabrication, and mechanical characterization of FGLS using AlSi10Mg, targeting potential biomedical applications. Three advanced lattice topologies were investigated: Gyroid, Split-P (a TPMS-derived surface), and Stochastic Voronoi, selected for their known mechanical performance and bioinspired architectures. Tensile (dog-bone shaped) and compression (cubic) specimens were fabricated via LPBF, with functional gradation introduced by varying strut and wall thickness along the specimen length. The mechanical properties, including elastic modulus, ultimate tensile and compressive strength, and energy absorption, were evaluated through quasi-static tensile and compression tests. High-resolution computed tomography (CT) scans were used to capture the as-built geometry, verify dimensional accuracy, and identify potential manufacturing defects. These images were further analyzed to assess internal fidelity, strut thickness deviations, and porosity, supporting the mechanical testing with geometric validation. This study fills a critical gap by directly comparing Gyroid, Split-P, and Stochastic Voronoi FGLS structures, all fabricated identically but with varying design parameters.