Laser additive manufacturing of metallic lattice structures: material-structure-property concept, and future perspective
1 Department of Electrical Engineering, Faculty of Engineering, Universiti Malaya, Kuala Lumpur 50603, Malaysia
2 Centre of Printable Electronics, Universiti Malaya, Kuala Lumpur 50630, Malaysia
3 Department of Biomedical Engineering, Faculty of Engineering, Universiti Malaya, Kuala Lumpur 50603, Malaysia
4 Department of Biochemistry, Faculty of Science, Universiti Malaya, Kuala Lumpur 50603, Malaysia
5 School of Optical and Electronic Information, Huazhong University of Science and Technology, Wuhan 430074, China
6 Institute of Advanced Studies, Universiti Malaya, Kuala Lumpur 50630, Malaysia
7 Institute of Advanced Materials and Technology, Guangdong University of Technology, Guangzhou, 510006, China
8 Faculty of Mechanical & Automotive Engineering Technology, Universiti Malaysia Pahang Al-Sultan Abdullah, Pekan 26600, Malaysia
9 Centre for Advanced Composite Materials (CACM), Universiti Teknologi Malaysia (UTM), Johor 81310, Malaysia
  • Volume
  • Citation
    Sun B, Zheng , Liu H, Wan Muhamad Hatta S, Yang , et al. Laser additive manufacturing of metallic lattice structures: material-structure-property concept, and future perspective. Adv. Manuf. 2026(2):0006, https://doi.org/10.55092/am20260006. 
  • DOI
    10.55092/am20260006
  • Copyright
    Copyright2026 by the authors. Published by ELSP.
Abstract

Metallic lattice structures have emerged as revolutionary lightweight materials with exceptional specific strength and multifunctional capabilities, particularly in aerospace applications. This review comprehensively examines the state of the art in laser additive manufacturing (LAM) of metallic lattice structures, focusing on selective laser melting (SLM) and electron beam melting (EBM). We critically analyze recent advances in materials development, including nickel-based superalloys (GH4169/IN718, K465), titanium alloys (Ti-6Al-4V), and functionally graded composites. The review addresses key design considerations, including unit cell topology optimization, node reinforcement strategies, and gradient structures. We examine mechanical properties under various loading conditions, thermal management capabilities, and failure mechanisms through both experimental and numerical perspectives. Advanced detection methods, including micro-CT imaging and AI-based defect identification, are evaluated for quality assurance. Critical challenges, including surface roughness control, residual stress management, and size limitations, are discussed alongside emerging opportunities in machine-learning-assisted design and multi-material systems. This review provides essential insights for researchers and engineers seeking to advance lattice-structured applications in next-generation aerospace systems.

Keywords

lattice structures; additive manufacturing; selective laser melting; mechanical properties; aerospace applications; non-destructive testing

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