Virtual manufacturing of lattice struts by part-scale multi-physics model towards full process chain simulation of laser powder bed fusion

Lattice structures fabricated by Laser Powder Bed Fusion (LPBF) are critical for lightweight applications in aerospace, biomedical, and transportation. However, LPBF's multi-physical interactions inevitably induce geometric defects (radius deviation, waviness, surface roughness) in lattice struts, significantly altering mechanical properties and hindering accurate prediction with idealised models. While computed tomography (CT) based methods can capture defects, they incur high costs, computational burden, and lack direct physical prediction. Existing multi-physics simulations are often time-consuming for complex lattice geometries. This study develops an integrated virtual manufacturing framework for lattice struts, employing a part-scale multi-physics model to accurately predict process-induced geometric defects. Crucially, by incorporating these virtually manufactured struts with embedded defects into finite element models, the framework significantly enhances predictive accuracy for mechanical behaviour. This integrated approach, combining virtual manufacturing, defect assessment, and performance evaluation, ensures the production of high-quality, cost-effective lattice parts by enabling pre-production optimisation of LPBF design and process parameters. Furthermore, this represents a foundational step towards the full process chain simulation of virtual manufacturing.