Designing Additive Manufacturing Lattice Structures: A Mechanics-Based Framework Linking Strut Behaviour to Structural Performance in H13 Tool Steel

Designing Additive Manufacturing Lattice Structures: A Mechanics-Based Framework Linking Strut Behaviour to Structural Performance in H13 Tool Steel | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Designing Additive Manufacturing Lattice Structures: A Mechanics-Based Framework Linking Strut Behaviour to Structural Performance in H13 Tool Steel Joe Elambasseril, Milan Brandt This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-9383504/v1 This work is licensed under a CC BY 4.0 License Status: Posted Version 1 posted You are reading this latest preprint version Abstract Laser Powder Bed Fusion (LPBF) enables the fabrication of complex lattice structures with tailored mechanical performance; however, the interplay between architecture, surface condition, and post-treatment remains insufficiently understood, particularly at the micro-strut scale. This study presents a mechanics-based framework linking strut-scale bending behaviour to lattice-scale mechanical response in LPBF H13 tool steel. Micro-struts with diameters ranging from 300 µm to 1 mm, along with stochastic lattice structures of varying relative densities, were fabricated and subjected to comprehensive mechanical testing, including four-point bending, tensile, fatigue, and compression tests. The effects of TiN coating and heat treatment were systematically evaluated on as-fabricated surfaces. The results demonstrate that four-point bending of isolated struts provides a direct representation of bending-dominated deformation in lattice architectures, enabling a physically meaningful interpretation of lattice behaviour. A clear size-dependent transition in mechanical response is observed, where surface effects dominate the strength and failure of smaller struts, while bulk material properties govern larger structures. TiN coating enhances strength and fatigue resistance through surface hardening and induced compressive stresses, whereas heat treatment improves ductility and fatigue life by modifying the underlying microstructure. At the lattice scale, reductions in strut length and modifications to architecture significantly increase compressive strength and stiffness by suppressing buckling and redistributing load paths. The combined findings establish a design framework integrating geometry, surface engineering, and thermal post-treatment, providing a pathway for tailoring mechanical performance in LPBF lattice structures. This work establishes a predictive, mechanics-based design framework for tailoring the performance of additively manufactured lattice structures, with applicability beyond H13 tool steel. Additive manufacturing H13 tool steel Lattice structures Mechanical behaviour Size effect Buckling behaviour Full Text Additional Declarations No competing interests reported. Cite Share Download PDF Status: Posted Version 1 posted You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. Our growing team is made up of researchers and industry professionals working together to solve the most critical problems facing scientific publishing. Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-9383504","acceptedTermsAndConditions":true,"allowDirectSubmit":true,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":633558367,"identity":"887d83fc-a817-43ba-a460-f763f0bcdf36","order_by":0,"name":"Joe Elambasseril","email":"data:image/png;base64,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","orcid":"","institution":"RMIT University","correspondingAuthor":true,"prefix":"","firstName":"Joe","middleName":"","lastName":"Elambasseril","suffix":""},{"id":633558368,"identity":"1136cd7e-04db-47ff-8d5d-be8150cbf872","order_by":1,"name":"Milan Brandt","email":"","orcid":"","institution":"RMIT University","correspondingAuthor":false,"prefix":"","firstName":"Milan","middleName":"","lastName":"Brandt","suffix":""}],"badges":[],"createdAt":"2026-04-11 00:08:22","currentVersionCode":1,"declarations":"","doi":"10.21203/rs.3.rs-9383504/v1","doiUrl":"https://doi.org/10.21203/rs.3.rs-9383504/v1","draftVersion":[],"editorialEvents":[],"editorialNote":"","failedWorkflow":false,"files":[{"id":108492359,"identity":"b438700b-e9ab-4b49-883a-440ada3aac7d","added_by":"auto","created_at":"2026-05-05 09:57:34","extension":"pdf","order_by":1,"title":"","display":"","copyAsset":false,"role":"manuscript-pdf","size":1311035,"visible":true,"origin":"","legend":"","description":"","filename":"ManuscriptPIAM.pdf","url":"https://assets-eu.researchsquare.com/files/rs-9383504/v1_covered_ad965ff4-b2af-48ab-9680-575b624c8d30.pdf"}],"financialInterests":"No competing interests reported.","formattedTitle":"Designing Additive Manufacturing Lattice Structures: A Mechanics-Based Framework Linking Strut Behaviour to Structural Performance in H13 Tool Steel","fulltext":[],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":false,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":false,"hideJournal":true,"highlight":"","institution":"","isAcceptedByJournal":false,"isAuthorSuppliedPdf":true,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":false,"isPdf":true,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"researchsquare","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":true,"externalIdentity":"","sideBox":"","snPcode":"","submissionUrl":"/submission","title":"Research Square","twitterHandle":"researchsquare","acdcEnabled":true,"dfaEnabled":false,"editorialSystem":"","reportingPortfolio":"","inReviewEnabled":false,"inReviewRevisionsEnabled":true},"keywords":"Additive manufacturing, H13 tool steel, Lattice structures, Mechanical behaviour, Size effect, Buckling behaviour","lastPublishedDoi":"10.21203/rs.3.rs-9383504/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-9383504/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003eLaser Powder Bed Fusion (LPBF) enables the fabrication of complex lattice structures with tailored mechanical performance; however, the interplay between architecture, surface condition, and post-treatment remains insufficiently understood, particularly at the micro-strut scale. This study presents a mechanics-based framework linking strut-scale bending behaviour to lattice-scale mechanical response in LPBF H13 tool steel.\u003c/p\u003e \u003cp\u003eMicro-struts with diameters ranging from 300 \u0026micro;m to 1 mm, along with stochastic lattice structures of varying relative densities, were fabricated and subjected to comprehensive mechanical testing, including four-point bending, tensile, fatigue, and compression tests. The effects of TiN coating and heat treatment were systematically evaluated on as-fabricated surfaces.\u003c/p\u003e \u003cp\u003eThe results demonstrate that four-point bending of isolated struts provides a direct representation of bending-dominated deformation in lattice architectures, enabling a physically meaningful interpretation of lattice behaviour. A clear size-dependent transition in mechanical response is observed, where surface effects dominate the strength and failure of smaller struts, while bulk material properties govern larger structures. TiN coating enhances strength and fatigue resistance through surface hardening and induced compressive stresses, whereas heat treatment improves ductility and fatigue life by modifying the underlying microstructure.\u003c/p\u003e \u003cp\u003eAt the lattice scale, reductions in strut length and modifications to architecture significantly increase compressive strength and stiffness by suppressing buckling and redistributing load paths. The combined findings establish a design framework integrating geometry, surface engineering, and thermal post-treatment, providing a pathway for tailoring mechanical performance in LPBF lattice structures. 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