Multidimensional Phononic Bandgaps in Three-Dimensional Lattices for Additive Manufacturing.

We report on numerical modelling of three-dimensional lattice structures designed to provide phononic bandgaps. The examined lattice structures rely on two distinct mechanisms for bandgap formation: the destructive interference of elastic waves and internal resonance. Further to the effect of lattice type on the development of phononic bandgaps, we also present the effect of volume fraction, which enables the designer to control the frequency range over which the bandgaps exist. The bandgaps were identified from dispersion curves obtained using a finite element wave propagation modelling technique that provides high computational efficiency and high wave modelling accuracy. We show that lattice structures employing internal resonance can provide transmissibility reduction of longitudinal waves of up to -103 dB. Paired with the manufacturing freedom and material choice of additive manufacturing, the examined lattice structures can be tailored for use in wide-ranging applications including machine design, isolation and support platforms, metrology frames, aerospace and automobile applications, and biomedical devices.

Loose powder detection and surface characterization in selective laser sintering via optical coherence tomography.

Defects produced during selective laser sintering (SLS) are difficult to non-destructively detect after build completion without the use of X-ray-based methods. Overcoming this issue by assessing integrity on a layer-by-layer basis has become an area of significant interest for users of SLS apparatus. Optical coherence tomography (OCT) is used in this study to detect surface texture and sub-surface powder, which is un-melted/insufficiently sintered, is known to be a common cause of poor part integrity and would prevent the use of SLS where applications dictate assurance of defect-free parts. To demonstrate the capability of the instrument and associated data-processing algorithms, samples were built with graduated porosities which were embedded in fully dense regions in order to simulate defective regions. Simulated in situ measurements were then correlated with the process parameters used to generate variable density regions. Using this method, it is possible to detect loose powder and differentiate between densities of ±5% at a sub-surface depth of approximately 300 µm. In order to demonstrate the value of OCT as a surface-profiling technique, surface texture datasets are compared with focus variation microscopy. Comparable results are achieved after a spatial bandwidth- matching procedure.