Deformation analysis and manufacturability of Ti6Al4V gyroid lattice structure produced by laser powder bed fusion

Triply periodic minimal surface (TPMS) lattice structures, particularly the gyroid structure, offer promising mechanical performance for lightweight, multifunctional applications due to their continuous topology and high strength-to-weight ratios. In this study, a systematic parametric analysis was conducted to evaluate the influence of unit cell size and strut thickness on the mechanical behavior and manufacturability of Ti6Al4V gyroid structures fabricated via laser powder bed fusion (LPBF) and tested under quasi-static strain rates. Twenty-four distinct lattice configurations were additively manufactured and subjected to quasi-static compression tests, complemented by finite element simulations. The results reveal that smaller unit cells and increased strut thickness significantly enhance the elastic modulus, yield strength, and energy absorption capacity of the structures. A positive correlation was observed between mechanical properties and strut thickness, while a negative correlation emerged with increasing unit cell size. Manufacturing accuracy was evaluated by comparing designed and as-built volume fractions, supported by scanning electron microscopy (SEM) analysis, indicating improved geometric fidelity at higher strut thicknesses. Notably, the gyroid structure with a 3 mm unit cell and 0.25 mm strut thickness exhibited peak performance, yield strength of 168.7 MPa, and compressive strength of 192.70 MPa. These findings provide valuable insight into the design-performance relationship in TPMS lattices and contribute to the optimization of architected materials for structural applications.