Unit cell manufacture by blown powder directed energy deposition

Abstract

Lattice structures manufactured by additive manufacturing show unique promise to alter existing components to improve the thermo-mechanical properties of the base structure. In the present study, the manufacture of a self-supporting lattice structure by blown powder directed energy deposition was explored. Converging struts were manufactured using multiple lean angles to facilitate the self-supporting structure and to avoid machine-part collisions. The struts showed near uniform straightness relative to a fitted line with a maximum deviation of 1mm at a lean angle of 10°. Micro–hardness and porosity evaluation results showed no significant variation along the struts.