| Abstract Scope |
TPMS-based lattices enable design opportunities for improving performance in structural and thermal applications, but their complex curvature, overhangs, varying thickness, and relatively thin walls make production using large format metal additive processes challenging. Sand casting is a mature and scalable process, but we cannot feasibly produce molds of TPMS-based lattices with traditional metalcasting patterns. Using binder jetting, sand molds with the overhangs and blind features needed for lattices can be produced directly without patterns. However, casting lattice structures comes with other potential concerns. The large surface area and tortuous paths for metal flow can lead to misruns, cold shuts, and other defects. This work studies the relative castability of different TPMS-based lattices to inform future sand casting design efforts. We compare both skeletal and surface TPMS-based lattices at matched volume fractions using otherwise identical part and gating design, simulating mold fill and solidification to assess defect formation and overall castability. |