A continuum approach to simulating the sintering of 3D-printed objects with natural anisotropic honeycomb lattice structures

Abstract

Honeycomb lattice structures are commonly used to optimize the weight-to-strength ratio in 3D printing, but during high-temperature sintering, these parts are prone to distortions that current tools struggle to predict. To address this, we developed a comprehensive lattice/shell sintering model. Our approach calculates the effective sintering moduli of the honeycomb using virtual shear and isostatic tests, accounting for both material and structural anisotropy. A key challenge was ensuring synchronized sintering behavior between the thick shell and lattice, preventing distortion errors. This continuum simulation method, validated through bar sintering tests, significantly reduces computational demands, making it ideal for design and optimization studies.