Dimensional accuracy and compression behaviour of copper LPBF lattices: Digital Volume Correlation characterization
(2026) European Mechanics of Materials Conference 20 — Location: Florence, Italy (27.May.2026)
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- Authors
- Abstract
- Laser Powder Bed Fusion (LPBF) of pure copper enables manufacturing of complex geometries. Because of the excellent electrical and thermal conductivity, this technology is gaining attraction in thermal management solutions and electromagnetic applications. However, a major drawback of copper is its high density, while weight restrictions are frequently imposed for many applications. Strut-based lattices are proposed as a possible solution, aiming to achieve a weight reduction while maintaining local high performance. In addition, these lattices provide a high strength-to-weight ratio, as well as allowing for local densification leading to tuned local properties. In this study, Body Centered Cubic (BCC) lattices were manufactured with a Unit Cell Size (UCS) of 2 mm and a designed Volume Fraction (VF) of 25%. Additionally, adapted scanning strategies were introduced, including continuous contour scanning mode, to further increase dimensional accuracy, relative density and reduce shape irregularities. Furthermore, point scan BCC lattices with UCS 1 and 2 mm were built to identify the physical minimum strut diameter, which acts as the lower limit for compensating the CAD-part mismatch. Computed tomography (CT) scans will visualize the porosity distribution and quantify the deviation from the designed geometry. The effect of the newly implemented contour mode on deformation behaviour and the mechanical properties of BCC lattices with UCS 2 mm (both VF 25% and points scan) is investigated with the use of in-situ CT compression testing. Digital Volume Correlation is performed to track strain concentrations and understand deformation and failure mechanisms. In addition, introducing contour mode drastically improved their surface quality and reducing VF mismatch. The contour mode improvements are attributed to reduced overheating at the connection point of subsequent vectors, causing less melt pool inhomogeneity, which in turn reduces surface irregularities. It is hypothesized that lattices built with contour mode will possess lower compressive stress concentrations and exhibit a more predictable deformation behaviour. These improvements for strut-based copper lattices are crucial to obtain more reliable and accurately manufactured products.
- Affiliations
KULeuven Department of Mechanical Engineering - MaPs
Citations
Vanherf, F., Simar, A., & Van Hooreweder, B. (2026, May 29). Dimensional accuracy and compression behaviour of copper LPBF lattices: Digital Volume Correlation characterization. European Mechanics of Materials Conference 20, Florence, Italy. https://hdl.handle.net/2078.5/276830