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  1. FDA STEM Outreach, Education and Engagement

Design Parameter Effects on Additively Manufactured Ti-6AL-4V Lattice

Authors:
Poster Author(s)
Andrew Cunningham, Matthew Schwerin, Matthew Di Prima, Peter Liacouras, Daniel Porter 
Center:
Contributing Office
Center for Devices and Radiological Health

Abstract

Poster Abstract

Lattice structures have become more prevalent in the medical device field due to the potential benefits of promoting biological fixation through porous pathways and the capability to mimic the mechanical properties of bone.  The complex architecture of these structures makes them difficult to manufacture using traditional methods, and Additive Manufacturing (AM) is generally a more preferred method to produce these structures.  The design of lattice structures constitutes a wide range of variables, which makes it difficult to assess the validity of extrapolated performance assumptions.  It is therefore important to understand how variables such as relative density, strut diameter, heat treatment, and loading modalities of lattice cell structures can affect the mechanical response of the bulk structure.  Due to the complexity of these structures, it is also imperative to understand the current limitations of simulating the performance of these lattices using Finite Element Analysis (FEA). Cubic lattice samples are generated using Body Centered Cubic (BCC) unit cells with various relative densities and cell lengths.  An FEA study is conducted to determine the degree of accuracy between simulated and experimental quantities of interest (QOI).  The QOI collected for this study are: Von Mises Stress and Y Axis Reaction Force, both with respect to Y Axis Deformation of the structure. The design parameters being investigated are: relative density and cell length. Static loading modalities and post processing heat treatment through Hot Isostatic Pressing (HIP) are also investigated.  The test samples in this study are fabricated using a medically relevant metal alloy, Ti-6AL-4V (Grade 5), by Electron Beam Powder Bed Fusion (E-PBF).  Results of this study will help allow a more thorough understanding of the structural impacts caused by varying lattice design parameters and the potential differences in mechanical properties between experimental and simulated AM lattice structures.

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