Mechanical and Thermal Performance of SLA-Printed Ceramic-Reinforced Lattice Structures: A Topology-Material Synergy Approach

Additive manufacturing (AM), particularly stereolithography (SLA), has emerged as a transformative technology capable of producing lightweight, complex structures for high-performance applications. However, limited knowledge exists regarding the combined effects of material composition and lattice topology on the mechanical and thermal behavior of SLA-printed components. This study addresses this gap by investigating the influence of ceramic nanoparticle reinforcement-using Al2O3, hBN, and SiC-alongside three distinct lattice geometries (simple cubic, diamond, and octahedral) on the performance of SLA-fabricated structures. A comprehensive experimental approach was adopted, incorporating tensile, compression, and Charpy impact testing, as well as thermogravimetric (TGA), derivative thermogravimetric (DTG), and differential thermal analyses (DTA). The results indicated that hBN-reinforced samples exhibited a 17.5% increase in tensile strength and a 10.66% reduction in thermal degradation rate, while Al2O3-enhanced samples demonstrated a 124.5% improvement in impact resistance. In contrast, SiC additives slightly reduced tensile strength and thermal stability. Among the lattice geometries, simple cubic structures achieved the highest compressive strength (up to 0.76 MPa with hBN), whereas diamond lattices provided a balance between strength and ductility. The study concludes that the synergistic selection of ceramic fillers and lattice topology can be strategically employed to design multifunctional components with enhanced mechanical and thermal properties for advanced applications such as aerospace, automotive, and energy-absorbing systems.