In automotive parts, medical implants, running shoes, and hiking backpacks, we’re seeing more and more 3D-printed components featuring lattice or honeycomb patterns. You might think these lattice structures are the latest innovation in 3D printing and design for additive manufacturing (DfAM), but in fact, we’re constantly surrounded by natural lattices. Think of honeycombs, snowflakes, fences, sponges, or even the Eiffel Tower!
Lattice structures are networks of interconnected nodes arranged in repeating or gradually varying patterns called cells. These designs offer benefits for both part performance and production. In traditional manufacturing, lattices are rare because the processes simply can’t produce such complex geometries. That’s where additive manufacturing truly shines, making lattices and 3D printing a perfect match.
A 3D printed lattice structure (Photo Credit: Sculpteo)
Before talking about 3D printing lattice structures, let’s first look at the different types of lattices. In principle, lattices are formed by connecting nodes with struts. Depending on how the nodes and struts are arranged, regular or irregular patterns can emerge. By adjusting the density of the struts, as well as the geometry and size of the cells, it’s possible to fine-tune properties such as elasticity or stiffness. There is a wide variety of lattice types, and ongoing research continues to develop ever more diverse and high-performing structures. However, the most common lattices can be grouped into a few main categories:
- Planar lattices: These lattices are based on a two-dimensional plane that forms a three-dimensional part. Since the layers are printed individually, they may need to be assembled afterward. This category includes tetrahedral patterns, Voronoi lattices, as well as rhombic and hexagonal lattices (for example, honeycombs).
- Truss lattices: These lattices are made of connected struts that form a network by linking the nodes, corners, or edges of the cells. The printed layers overlap and interlock. In some cases, the lattice may need to be reinforced with support materials.
- TPMS lattices (Triply Periodic Minimal Surface): These lattices are based on a trigonometric equation that defines the cell geometry. The basic shape of these lattices can vary.
There is a wide variety of 3D-printed lattice structures (Photo Credit: Shenzhen JR Technologies)
Lattices can also be classified as periodic or stochastic. Periodic lattices maintain a uniform pattern throughout the structure, while stochastic lattices feature variations in cell shape, size, and arrangement to strengthen the structure in certain directions.
The choice of lattice depends on its intended purpose. The design takes into account suitable geometry and cell size, as well as the desired stiffness. Buckling behavior, that is how the structure deforms under pressure and in which directions, is also analyzed. In addition, designers often consider whether the lattice can absorb energy when it deforms.
Designing and 3D Printing Lattices
To design lattices for 3D printing, a specialized design tool is required. While some modeling software offers basic lattice functions, software focused on topological optimization or generative design is more reliable. Generative design calculates the optimal design based on the required part properties and the chosen printing method. If the design includes lattices, their cell shapes, density, and arrangement are also determined during this process.
Many tools are available to optimize 3D models and create lattice structures, including Autodesk Within, nTop by nTopology, Meshify, 4D_Additive by Core Technologie, Netfabb, and HyDesign by Hyperganic. The choice of design depends on the application, material, and printing technology.
With HyDesign by Hyperganic, you can design lattice structures (Photo Credit: Hyperganic)
Lattice structures are much easier to produce with 3D printing because they are often very complex and delicate. In addition, printing lattices is faster than printing solid structures. In theory, a wide range of materials and printing technologies can be used, but each process has its own requirements:
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In FDM and SLA printing, support structures are needed for large lattice structures.
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With powder-based processes such as SLS or MJF, sufficient access points must be provided to allow effective powder removal.
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In DMLS, additional supports must be considered to avoid the 2 mm limit for unsupported bridges.
These requirements are generally taken into account during the design phase.
The desired part properties and its application are incorporated into the design of the lattice structure (Photo Credit: nTopology)
Challenges and Benefits of Lattices
The main challenges include cell orientation, the spacing between beams, and the angles relative to the print platform. The lattice must both meet the objectives of the final part and be manufacturable. In addition, digital files for lattice designs can be very large (over 1 GB) and require significant computing power for simulations.
However, the benefits are numerous:
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Material savings: Lattices allow for lighter parts, reducing costs and improving performance, especially in lightweight structures.
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Improved quality: Lattices enhance shock absorption, increase flexibility, or, conversely, reinforce stiffness to make products more durable.
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Specific applications: Lattices increase heat exchange surfaces in heat exchangers and promote bone growth in medical implants.
Toucan Beak, a 3D-printed heat exchanger with lattice structures inside (Photo Credit: Aidro)
Applications of 3D Printed Lattices
Let’s now look at some application areas where 3D-printed lattices show their potential. In the medical field, lattices are used not only for implants, as mentioned earlier, but also for prosthetics and orthotics to optimize weight, strength, and comfort.
Lattice structures are especially advantageous in applications where high performance and light weight are essential, such as in the automotive, aerospace, and space industries. For example, using lattices and the “Shell & Lattice” feature in nTop, Aerojet Rocketdyne was able to reduce the weight of a quad engine block by 67 percent and lower its production cost by 66 percent.
Aerojet Rocketdyne engine block using lattice structures to reduce weight (Photo Credit: nTopology)
Lattices are also gaining importance and popularity in sports and consumer goods. Increasingly, 3D printed lattice structures are being used in protective gear and padding. These lattices appear in bicycle saddles, helmet padding, protective clothing, and midsole soles for shoes. In running shoes in particular, they are expected to improve energy transfer and overall performance.
The same logic applies to car seats and backpacks. For example, outdoor equipment specialist Oechsler used Materialise’s Magics software to enhance the comfort of its innovative backpacks with lattice structures. Furniture is also beginning to incorporate lattices, although in this case aesthetics often take priority over lightness.
These examples show that lattices are already present in many applications. With the ongoing industrialization of 3D printing and continuously evolving design possibilities, this trend is expected not only to continue but also to grow stronger in the future.
Lattice structures for shock absorption and improved comfort (Photo Credit: Oechsler)
What are your thoughts on lattice structures? How have you used them in your designs? Let us know in the comments or on our LinkedIn or Facebook pages! Plus, don’t forget to sign up for our free weekly Newsletter to get the latest 3D printing news straight to your inbox. You can also find all our videos on our YouTube channel.
*Cover Photo Credit : Dassault Systèmes