Lattice structures are a game-changer in additive manufacturing. By replacing solid volumes with interconnected struts, they reduce part weight while maintaining strength. However, as we push the limits of lightweight design, lattice structures, especially those with thin struts, bring new challenges related to thermal distortion.
Thin lattice struts are particularly vulnerable during metal 3D printing because of uneven heat buildup. If these struts aren’t properly supported, balanced, or oriented, they can warp mid-print due to thermal stress and residual forces. This is especially true in large builds or high-power systems where heat isn’t uniformly dissipated across the platform.
Fortunately, engineers have a few tools to mitigate this. First, thermal simulations can identify where distortion is likely to occur, allowing design teams to reinforce specific nodes. Second, balancing thermal exposure through part orientation and scan strategy plays a major role. Lastly, applying post-processing techniques like stress-relief heat treatment can significantly reduce internal strain in the final part.
To get the full benefit of lattices without risking failure, teams must pair intelligent design with simulation and thermal management. By addressing distortion proactively, it’s possible to produce reliable, lightweight parts, ideal for aerospace, motorsports, and other weight-critical industries.