Doctoral Thesis

Research and Development of Additively Manufactured Lattice Structures

Final Thesis 5.43 MB Summary of Thesis 794.24 kB

Author of thesis: Ing. Jan Jaroš, Ph.D.

Acad. year: 2025/2026

Supervisor: doc. Ing. Daniel Koutný, Ph.D.

Reviewers: Dr. Fernando Gustavo Warchomicka, dr inż. Bartłomiej Wysocki

Abstract:

Developments in additive technologies have enabled the production of porous lattice structures from a wide range of metal alloys. These can be used to replace solid material and produce components with significantly reduced mass or higher heat dissipation. In addition, the combination of lattice structures and magnesium alloys potentially enables the production of biodegradable implants that promote bone tissue ingrowth and exhibit mechanical properties close to those of bone tissue due to the magnesium alloy. For the potential application of such components in various industries, it is necessary to ensure high-quality production. This is associated with a high relative material density, low surface roughness and high dimensional accuracy. Lattice structures are difficult to process after production, which places high demands on the production itself. Laser powder bed fusion need the selection of suitable process parameters that lead to a minimization of imperfections. This dissertation therefore focuses on the production of lattice structures with the aim of minimizing imperfections as much as possible. The geometry of the lattice structures is divided into smaller parts in order to understand the influence of the manufacturing parameters on the formation of imperfections. In the first phase, manufacturing is focused on the strut geometry. The contour strategy is used, which seems to be suitable for manufacturing parts with low volume and round cross-section. As this is the base part of the structure, a good processable aluminum alloy AlSi10Mg is used to understand well the effects of the process parameters. The next phase focuses on the geometry of the unit cell, for which the magnesium alloy WE43 is used. In the last phase, the effect of contour and hatch strategies on the imperfections and mechanical properties of the lattice structures produced from WE43 magnesium alloy is investigated. The results confirm that by adjusting the process parameters, it is possible to produce lattice structures even from a difficult-to-process material such as a magnesium alloy. The relative density of the material reached more than 99.5% and the Young's modulus was 40 GPa. The described effects of the process parameters on the formation of imperfections could therefore help to ensure that porous structures can be used for more applications in the future.

Keywords:

Laser beam powder bed fusion, lattice structures, aluminum alloy, magnesium alloy, material quality, relative material density, surface roughness, dimensional accuracy, mechanical properties

Date of defence

16.09.2025

Result of the defence

Defended (thesis was successfully defended)

znamkaPznamka

Process of defence

Disertační práce splňuje požadavky plynoucí z par. 47 Zákona č. 111/1998 Sb., Zákona o vysokých školách a o změně a doplnění dalších zákonů a z článku 42 Studijního a zkušebního řádu Vysokého učení technického v Brně. Obsahuje původní výsledky uveřejnění mj. ve třech článcích v impaktovaném časopise.

Language of thesis

English

Faculty

Department

Study programme

Design and Process Engineering (D-KPI-P)

Composition of Committee

prof. Ing. Martin Hartl, Ph.D. (předseda)
doc. Ing. Petr Svoboda, Ph.D. (člen)
Dr. Fernando Gustavo Warchomicka (člen)
Ing. Ivo Šulák, Ph.D. (člen)
dr inż. Bartłomiej Wysocki (člen)

Supervisor’s report
doc. Ing. Daniel Koutný, Ph.D.

viz. posudek v PDF
File inserted by supervisor Size
Posudek vedoucího práce [.pdf] 4,99 MB

viz. posudek v PDF
File inserted by the reviewer Size
Posudek oponenta [.pdf] 447,67 kB

Reviewer’s report
dr inż. Bartłomiej Wysocki

viz. posudek v PDF
File inserted by the reviewer Size
Posudek oponenta [.pdf] 380,81 kB

Responsibility: Mgr. et Mgr. Hana Odstrčilová