Twist design of lattice structure fabricated by powder bed fusion to adjust the energy absorption behavior

Additive manufactured lattice structures offer great potential for impact resistance applications. They exhibit excellent energy absorption characteristics during the elasto-plastic deformation process, providing protection to internal devices. However, the mechanical response of lattice structures undergoes substantial variations during the deformation process, thereby imposing limitations on their energy absorption behavior. This study introduces a novel twist design to modify the energy absorption behavior of rectangular and hollow cylindrical lattice structures. Powder bed fusion was used to fabricate the twisted lattice structures. The study employed a combination of compressive simulations and experimental investigations to systematically explore the impact of the twist angle on the peak crushing force, energy absorption, and crash load efficiency of the structures. Adjusting the twist angle results in a reduction of the peak crushing force and a transition towards a stable loading profile during the deformation process. Moreover, the crash load efficiency is also reduced. The twist design concept presented in this paper provides insight into designing and optimizing lattice structures for energy absorption applications.