Lightweighting is a central design goal in industries like aerospace, drones, and robotics, where reducing mass translates directly to better performance. In this case study, a drone arm previously machined from solid metal was redesigned using a lattice infill structure and produced via selective laser melting (SLM). The result: a 40% reduction in weight without compromising mechanical stiffness. This change alone extended flight time, improved agility, and reduced vibration, all while maintaining the structural demands of the application.
Lattice structures excel because they distribute loads efficiently while using less material. Unlike solid parts, which carry redundant internal volume, lattices maintain strength by forming a truss-like internal architecture. Engineers can fine-tune cell size, wall thickness, and geometry to meet specific stress and frequency response targets. These optimizations are made possible only through additive manufacturing, which enables printing geometries that are impossible to machine.
Beyond weight savings, lattice infill also introduces benefits in thermal management and vibration damping. The increased surface area can help with cooling, while the distributed mass and stiffness reduce resonance and harmonics during flight. This makes lattice infill not just a structural strategy, but a multi-functional tool in performance-driven design. The key lies in simulation and testing, each lattice must be validated for the specific loads and dynamics of its application.
Ultimately, this drone arm proves how metal AM can elevate design beyond the limits of subtractive manufacturing. When every gram counts, advanced design techniques like lattice infill unlock a new level of efficiency. What was once solid can now be smart.