Effect of cell size on the environmental impact of gyroid lattice structures

Additive manufacturing has transformed modern production by enabling the precise, layer-by-layer creation of complex geometries, surpassing the limitations of traditional methods. A key application is the development of lattice structures, particularly Triply Periodic Minimal Surface Gyroid structures, which have attracted considerable attention for their unique properties, in different sectors from structural applications to heat exchange systems. As technological advancements continue, sustainability has become a critical focus in the manufacturing field, driven by both environmental and managerial factors. Consequently, the industry is increasingly adopting solutions that aim to reduce energy consumption and resource use, promoting cost-effective, eco-friendly production methods. This study investigates the impact of varying cell sizes in gyroid lattice structures, produced via Laser Powder Bed Fusion of metals, on sustainability and productivity. Four cubic samples with different cell sizes but constant wall thickness were analyzed. Additionally, a cradle-to-gate Life Cycle Assessment was performed to model the process and quantify the environmental impact, particularly carbon emissions. The results show that while smaller cell sizes enhance performance in engineering applications, they also lead to increased manufacturing time and higher energy consumption, posing challenges for sustainable production.