A Methodology for Computed Tomography-Based Non-Destructive Geometrical Evaluations of Lattice Structures by Holistic Strut Measurement Approach

The presence of lattice structures is increasing in the manufacturing domain especially in the air/spacecraft and biomedical applications due to their advantages of high strength-to-weight ratios, energy absorption, acoustic and vibrational damping, etc. Dimensional accuracy of a lattice structure is one of the most important requirements to meet the desired functionality as there could be significant deviations in the as-produced part from the designed one. Evidently, an approach (non-destructive) to evaluate the dimensional accuracy of all the elements and eventually the lattice quality is of great significance. X-ray computed tomography (CT) has emerged as a promising solution in the field of industrial quality control over the last few years due to its non-destructive approach. In this work, we propose a methodology for geometrical evaluations of a lattice structure by measuring the deviation in the shape and size of its strut elements holistically. The acquired CT data of the complete lattice are extracted in the form of a point cloud and then segmented and stored as a single strut element with unique identification so that measurements can be performed on the strut individually. As demonstrated with a metallic BCCz-type lattice structure, the methodology helps in critical evaluation of its quality and the correlation with spatial position of the individual struts; e.g., the lattice exhibits large variations of shape among the inclined struts while the vertical struts possess consistency in their shape.