Correlation between as-designed and as-built Young's modulus of cubic regular, cubic irregular, and trabecular cellular materials

Laser powder bed fusion process is widely used in producing cellular materials for various applications. However, there are limitations in the process to produce high-porosity cellular materials with accuracy. A deviation is observed between the as-built and the as-designed geometrical parameters that lead to variation in the obtained stiffness of the cellular material. This study investigates the behavior of three cell topologies, cubic regular, cubic irregular, and trabecular under as-designed and as-built configurations to study their Young's modulus variation. The obtained results are compared with the ideal predictions of the Gibson–Ashby law to evaluate the deviation. Eventually, a linear correlation was developed between the as-designed and as-built Young's modulus to generate a database to select the as-designed geometry/properties to obtain the required as-built geometry/properties.