Generative lattice structures designed for critical application via powder bed fusion additive manufacture techniques

  • Paul Tallon

Student thesis: Master's Thesis


This thesis considers the viability of an additive manufacturing approach for complex generative lattice structures for a critical application in a turbo charger housing containment band.
Specimens of varying lattice structure thicknesses were produced in additive 316lL on a Renishaw AM500 and analysed with x-ray computational tomography (XCT) and third-party programmes for porosity, deviation from CAD models, general cohesion of the internal structure and surface quality. The output physical structures produced by simulated finite element analysis were subject to a point load using a coaxial load machine to verify which structures would most efficiently attenuate an equivalent impact force as described by the literature section.
The outcome of these tests proves that there is scope for the usage of additive manufacturing in critical application, however more testing is needed to properly pinpoint the best practice for printing, since the sample set that could be produced was insufficient. As a caveat to this, there may not be a perfect orientation for a complete unit when built, as there will always be some section of the internal structure that is not in the optimal position relative to the substrate or laser profile. Therefore, there could be many other future research opportunities and investment into several elements of this thesis for proper validation and application in said field.
Date of Award11 Jan 2023
Original languageEnglish
SupervisorJohn Allport (Main Supervisor) & Ertu Unver (Co-Supervisor)

Cite this