Lattice structures are a type of repeating three-dimensional (3D) structure that is commonly found in nature. The name "lattice" is given to the arrangement of the repeating units in a three-dimensional space. The structures are created by connecting a series of points in 3D space. 

Lattices are classified into two types: primitive has one lattice point per unit cell, whereas non-primitive has more than one lattice point per unit cell. 

Lattice structures are often used in 3D printing because they provide a way to create complex shapes with a minimum amount of material. This article discusses the advantages of a lattice structure, how to create a lattice structure and applications of 3D printed lattices. 

Before deep diving into designing lattice structures for 3D printing, you need to understand what is a lattice structure. Let us first understand the different lattice structure types:

The difference in each lattice structure is due to the way atoms are arranged in a regular form. The arrangement is of three types: 

The most common lattice type is the cubic lattice, which is made up of nodes arranged in a cube-like structure. Cubic lattices are incredibly strong and stiff, making them ideal for applications where strength and stiffness are critical. 

Another common type of lattice is the honeycomb lattice. Honeycomb lattices are made up of nodes that are arranged in a hexagonal structure. However, honeycomb lattices are not as strong and stiff as cubic lattices, so they are not typically used in applications where strength and stiffness are key.

Each lattice structure type has different characteristics and offers a number of advantages over traditional solid designs. Lattices are much lighter in weight than solids, making them ideal for applications where weight is a key factor, such as aerospace and aviation. Aeronautical and design engineers are always looking for aerospace materials that have a low density, so lattice structures are a great option in this area. 

Beam structures are also highly efficient in absorbing energy, making them ideal for impact-resistant applications such as protective gear. Since lattice structures are much more open than solid designs, they offer better airflow and heat dissipation making them ideal for use in electronic devices and other applications where heat management is a critical concern. In addition, lattice structures can be used to create aesthetically pleasing designs that would not be possible with solid structures. 

Once you understand the basics of lattices and the different types that are available, it's time to learn about how to use them in your 3D printing applications. For using lattice structures in your 3D printing applications, it is important that you first understand the basics of how lattices are created. Lattices are essentially three-dimensional networks of interconnected elements, or "nodes." These nodes can be of any shape or size, but they are typically spheres or cubes.

To create a lattice, nodes are connected together with beams. The number of beams connecting any two nodes is known as the "coordination number." The coordination number of a lattice can range from 6 to 12 (6 is for simple lattice structure, 8 is for bcc lattice, 12 is for fcc lattice and 12 is also for the hexagonal lattice structure.)  

The first step is to model your part using a CAD program. For this purpose, a number of different CAD programs are used, but many designers prefer to use Solidworks. Once your part is modeled, you'll need to generate a STL file. The most popular software for generating STL files is Meshlab due to its ability to process large unstructured meshes easily. 

After you have your STL file, you'll need to load it into a slicing program. Slicing programs are used to generate the G-code that is necessary to 3D print a part. The most popular slicing program is Cura due to its easy integration with SolidWorks and Autodesk Inventor. Cura has a modern interface with options of selecting Tree Supports - an option to experiment with different designs.

Once your STL file is loaded into a slicing program, you can select one of the custom options. This will cause the slicing program to generate a G-code file that contains instructions for printing a lattice.

Once your G-code file is generated, you'll need to load it into your 3D printer. Most 3D printers have the ability to print from G-code files, but if yours doesn't, you can use a program like Repetier Host to convert the G-code into a format that your printer can understand.

The printing process will begin once your G-code file is loaded into your 3D printer. Depending on the size and complexity of your part, it may take several hours to complete.

Once your part is printed, you'll need to remove it from the build plate and clean up any extra material attached to the design.  

After your part is cleaned up, your lattice structure is ready to be used for your application. You will need to experiment a few times to achieve your desired results. 

It is sensible to experiment with different designs on SolidWorks and test their properties by making design changes to save resources (3D printing material, electricity and your time). 

To test the effects of different lattice structures, compare the results using an Ansys Simulation (you can find many helpful tutorials on how to use Ansys Simulation on the internet.) After you have completed your design and are happy with the results, you can then 3D print your lattice structure. 

If the mesh time is very high for a particular lattice, the design might not be very efficient. Try to improve the design by playing around with different infill patterns and percentages. Remember to check for the specifications of your 3D printer and the nozzle size to make sure that your overall part dimensions are small enough so that the 3D printer can print it without any issues. 

3D Printing is an incredibly powerful tool that can be used to create and experiment with parts with varying strength, stiffness, and heat dissipation properties. Before you start working on your 3D design models, take a look at the applications of 3D printed lattices.  

The amazing part about using lattice structures for 3D Printing is that they can be tailored for different mechanical properties. The design constraints can be overcome and an automation process can be created that allows batch processing. 

Lattices provide superior strength-to-weight ratios and can be specifically designed to meet a given application's unique strength and stiffness requirements. Lattice structures are used in a wide range of industries to design new products, applications and ideas. Here are some recent examples that have captured our attention:

Optimizing the lattice structures can help achieve the set performance targets for various applications. Lattice structures have the potential to revolutionize the way we design and manufacture products. Our imagination only limits us!