METAMET project to 3D print metallic microlattices for lightweight parts

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A consortium of companies and organisations is embarking on METAMET, an 18-month project developing a digital framework for the design and additive manufacture of lattice metamaterial structures.

Example image shows a bespoke, additively manufactured engine lifting bracket. Use of additive manufacturing (AM) enabled the titanium component to be optimised for weight saving and material wastage, with emphasis on critical features and designs for AM - TWI

The project, funded by Innovate UK via the UK government’s Resource Efficiency for Materials and Manufacturing (REforMM) programme, is being carried out by Authentise, NS85Ltd, Holdson Limited and the Joining 4.0 Innovation Centre (J4IC), a partnership between Lancaster University and TWI Ltd. 

The aim of the project is to identify a comprehensive and traceable way of optimising 3D printed parts using lattices that can provide material properties including directional cooling, reduced vibration and enhanced crack resistance to parts.

Metallic microlattices can enable extremely lightweight structures, with high strength-to-weight ratios that also have energy absorption properties, mechanical strength, thermal management capacity and design versatility. Consequently, these lightweight structures appeal to industries including aerospace, automotive and transportation.

To utilise the properties of latices several challenges in design and manufacture need to be addressed, including the handling of intricate and geometrically complex structures, the identification of suitable materials; the need to develop new fabrication techniques, and addressing scale and size limitations to facilitate mass production while maintaining desired properties.

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The project will use advanced computational tools, optimisation techniques, material science expertise and innovative manufacturing approaches to overcome these challenges, and achieve the desired mechanical, acoustic or electromagnetic properties in lattice metamaterials.

R&D activities on METAMET will be targeted at delivering an end-to-end digital framework covering the entire spectrum of steps required to design and manufacture metallic microlattices. 

Work will include materials selection, such as aluminium, titanium and/or steel alloys; concept design of the lattice structure and cell geometry, design implementation using CAD; simulation and optimisation to evaluate properties such as the structure, behaviour, strength-to-weight and energy absorption capacity; additive manufacturing using powdered metal, post-processing; testing; and characterisation. 

Following validation of the design and fabrication stages, the final goal will be to scale up manufacturing for real-world deployment, via options such as the use of custom manufacturing equipment or partnering with specialised manufacturing facilities.

In a statement, Professor Darren Williams, director of J4IC, said: “This exciting new project…has the potential to offer substantial benefits to major industry in the manufacturing of lightweight parts and structures.

“As well as developing proprietary new technologies, METAMET will support the wider environmental goals of reduced materials consumption and carbon emissions by enabling the production of lightweight parts using less energy.  In turn, this will contribute to the lightweighting of larger structures and their fuel efficiency when operational.”

metallic microlattices