Influence of geometric and manufacturing parameters on the compressive behaviour of FFF lattices

Abstract

Lattice structures manufactured by fused filament fabrication (FFF) enable the mechanical response of architected materials to be tailored through geometric and manufacturing parameters. However, the relative importance of these factors across different lattice architectures remains insufficiently quantified within a consistent experimental framework. This study investigates the influence of geometric and manufacturing parameters on the compressive response of three lattice architectures (octet‐truss, re‐entrant and gyroid) manufactured from glycol‐modified poly(ethylene terephthalate). A full factorial design of experiments was employed as an exploratory screening approach to investigate the effects of the number of unit cells, wall thickness and layer height. Specific yield strength and specific energy absorption were evaluated, while analysis of variance and Lenth's method were used to identify and compare parameter‐related trends across the investigated architectures. Within the investigated parameter ranges, the octet and re‐entrant lattices exhibited clearer trends associated with geometric parameters, particularly wall thickness and number of unit cells, whereas no comparable effect was observed for layer height. The gyroid architecture showed a more homogeneous response, with the effects of the investigated parameters being less clearly resolved within the adopted experimental design. The results provide preliminary evidence that the relative influence of geometric and manufacturing parameters differs between lattice architectures. By comparing distinct topologies under consistent manufacturing and testing conditions, this exploratory study identifies parameter‐related trends that can support the design of future replicated experiments and more robust investigations of FFF lattice structures. © 2026 Society of Chemical Industry.