Short answer

When designing lattice structures for additive manufacturing, consider incorporating moderate perforations in the struts to achieve significant weight reduction without critically compromising mechanical integrity.

Field: Final Production
Source: Scientific Reports (2025)
Method: Experimental testing and Finite Element Analysis (FEA)
Sample: 5 lattice samples
Evidence: Strong effect

Introducing controlled perforations in lattice structures can significantly reduce material usage and weight without a proportional loss in mechanical strength and energy absorption. This final production research insight is drawn from a 2025 study published in Scientific Reports. Using Experimental testing and finite element analysis (fea) with 5 lattice samples, researchers explored how this design variable affects real-world outcomes. The key design takeaway: When designing lattice structures for additive manufacturing, consider incorporating moderate perforations in the struts to achieve significant weight reduction without critically compromising mechanical integrity.

Study

Final ProductionNew This WeekStrong effect

Perforated lattice structures offer up to 10% weight savings with minimal strength compromise

Introducing controlled perforations in lattice structures can significantly reduce material usage and weight without a proportional loss in mechanical strength and energy absorption.

Scientific Reports · 2025

Key Findings

01Solid struts (MPLS-0) yielded the highest strength, energy absorption density, and specific energy absorption.
02Increasing perforation size led to a decrease in strength and energy absorption metrics.
03Moderate perforations (MPLS-5 and MPLS-10) achieved approximately 83-75% of the solid strut strength while offering up to 10% weight savings.
04FEA simulations highlighted stress concentrations and torsional effects in hollow-strut lattices.

Application

Design takeaway

How to apply

When designing components for additive manufacturing that require a balance of strength and low weight, experiment with varying degrees of internal lattice perforation to find an optimal trade-off.

Project actions

01When designing lattice structures, consider how internal features like perforations affect material usage and structural integrity.
02Use simulation tools to predict the performance of modified lattice designs before physical prototyping.

Method & Evidence

AimTo investigate the effect of strut perforation geometry on the mechanical and energy absorption performance of periodic lattice structures fabricated via FDM.

MethodExperimental testing and Finite Element Analysis (FEA)

ProcedureFive lattice samples with varying strut-hole diameters were designed and fabricated using FDM with PLA+. These samples underwent uniaxial compression tests according to ISO 13,314 standards. Concurrently, FEA simulations were performed using Abaqus to model the mechanical behavior and energy absorption characteristics.

Sample5 lattice samples

ContextAdditive Manufacturing (Fused Deposition Modeling) of mechanical metamaterials.

Variables

IVStrut-hole diameter (perforation size)

DVYield strength, energy absorption density (EAD), specific energy absorption (SEA), efficiency of energy absorption (EAE)

CVLattice structure type, material (PLA+), fabrication method (FDM), testing standard (ISO 13,314)

Strengths & Limitations

Strengths

+Combines experimental validation with FEA simulations for comprehensive analysis.
+Investigates a range of perforation sizes to identify optimal trade-offs.

Limitations

The specific material and printing process used might not be representative of all applications. The study primarily examined compression, and other stress types could yield different results.

Reliability & validity

The use of standardized testing (ISO 13,314) and FEA simulations enhances the reliability and validity of the findings. However, the limited sample size of 5 distinct designs might restrict generalizability.

Think critically

How might the shape and distribution of perforations, beyond simple circular holes, further influence the mechanical and energy absorption properties of lattice structures?

Design Principles

"Optimize material usage by strategically modifying internal geometry to achieve desired performance characteristics."

This research provides a practical method for optimizing material use in additive manufacturing. By understanding the trade-offs between perforation size and structural performance, designers can create lighter components for applications where weight is critical, such as in aerospace and automotive industries, while maintaining necessary impact resistance.

What This Means for Your Design

You can make 3D printed lattice parts lighter by putting small holes in the struts, and you won't lose much strength if you don't make the holes too big.

How to use in your project

1.Use this research to justify design choices related to material reduction and structural optimization in your design project.

Add to My Project

Quick Cite

Paragraph starter

The investigation into modified periodic lattice structures reveals that controlled strut perforation can achieve significant weight savings (up to 10%) with only a moderate reduction in mechanical strength and energy absorption. This suggests a viable strategy for optimizing material usage in additive manufacturing for applications demanding lightweight yet robust components.

Source

Scientific Reports

Effect of strurt shape mechanical and absorption performance of periodic lattices

journal · 2025

View source

Questions About This Research

What does the research say about perforated lattice structures offer up to 10% weight savings with minimal strength compromise?: When designing lattice structures for additive manufacturing, consider incorporating moderate perforations in the struts to achieve significant weight reduction without critically compromising mechanical integrity. Evidence: Scientific Reports (2025).
Why does "Perforated lattice structures offer up to 10% weight savings with minimal strength compromise" matter for design?: This research provides a practical method for optimizing material use in additive manufacturing. By understanding the trade-offs between perforation size and structural performance, designers can create lighter components for applications where weight is critical, such as in aerospace and automotive industries, while maintaining necessary impact resistance.
How can designers apply this research?: When designing lattice structures for additive manufacturing, consider incorporating moderate perforations in the struts to achieve significant weight reduction without critically compromising mechanical integrity.
What were the main findings?: Solid struts (MPLS-0) yielded the highest strength, energy absorption density, and specific energy absorption.. Increasing perforation size led to a decrease in strength and energy absorption metrics.. Moderate perforations (MPLS-5 and MPLS-10) achieved approximately 83-75% of the solid strut strength while offering up to 10% weight savings.. FEA simulations highlighted stress concentrations and torsional effects in hollow-strut lattices.
What research method was used?: Experimental testing and Finite Element Analysis (FEA) with 5 lattice samples.
How strong is the evidence?: Evidence strength is rated Strong effect, based on a 2025 journal from Scientific Reports.
What should I do differently in my next project?: When designing components for additive manufacturing that require a balance of strength and low weight, experiment with varying degrees of internal lattice perforation to find an optimal trade-off.
What are the limitations?: The study focused on a specific material (PLA+) and fabrication method (FDM); results may vary with different materials and processes. The investigation primarily focused on uniaxial compression, and performance under other loading conditions was not detailed.