Printability analysis of low-density lattice structures in fused deposition modeling

Additive manufacturing (AM), particularly Fused Deposition Modeling (FDM), has revolutionized the production of complex geometries, offering cost-effective solutions for customized components. Among the materials used in FDM, Acrylonitrile Butadiene Styrene (ABS) stands out for its balance of mechanical properties, ease of processing, and adaptability. However, while the fabrication of moderate-to-high-density lattice structures has been well-documented, the geometric accuracy and printability of low-density lattice configurations remain a significant challenge. This study investigates the geometric fidelity of Cuboidal Body-Centered Cubic (BCC) lattice structures produced via FDM, with a focus on relative densities of 5%, 10%, and 15%. Two quantitative metrics – the Maximum Geometric Variability Index (GVImax) and the Average Geometric Variability Index (GVIavg) – are introduced to objectively assess deviations from nominal designs. Results show that configurations with lower cell size and density exhibit pronounced variability, with GVImax exceeding 25% and GVIavg above 10%. Conversely, configurations with higher cell size and density demonstrate superior geometric fidelity, achieving GVImax ≤ 10% and GVIavg ≤ 5%. Intermediate cases fall within 10–25% (GVImax) and 5–10% (GVIavg). Additionally, high-resolution imaging is employed to visually inspect representative lattice configurations, offering insight into defect morphology and geometric fidelity. The findings provide a comprehensive methodology for assessing the geometric precision of FDM-printed lattice structures, addressing a critical gap in the understanding of low-density configurations. This research enhances predictive modeling for lattice fabrication and supports applications in lightweight engineering fields, such as aerospace, where precision and weight reduction are crucial.