63324 2025 eng 1 16 320 article Elsevier B.V. 1 -- -- -- The mechanical properties of lattice geometries are known to be significantly influenced by a variety of manufacturing defects. This study investigates the influence of porosity on the mechanical behaviour of strut-based body-centred cubic (BCC) lattice structures produced with powder bed fusion with laser beam PBF-LB/P using PA2200 nylon powder. The study combines advanced techniques, including in-situ laboratory X-ray computed tomography (XCT), synchrotron XCT to visualise pores and roughness in high resolution at a single-cell level and image-based finite element analysis (FEA). The findings show that failure in thin-walled AM lattices is governed by the combined effects of porosity morphology, location, surface roughness, and cross-section reduction. The presence of internal porosity is found to attenuate both the amplitude of elastic modulus fluctuations and the severity of stress concentrations induced by surface irregularities. International Journal of Solids and Structures 0020-7683 10.1016/j.ijsolstr.2025.113488 urn:nbn:de:kobv:b43-633245 true journal-article https://www.elsevier.com/tdm/userlicense/1.0/ crossref doi-import 30.06.2025 Creative Commons - CC BY - Namensnennung 4.0 International Danilo Bruson Itziar Serrano-Munoz Tobias Fritsch Henning Markötter Manuela Galati eng uncontrolled Nylon Pa2200 eng uncontrolled Laser powder bed fusion (PBF-LB) eng uncontrolled Processing defects eng uncontrolled Synchrotron X-ray computed tomography (XCT) eng uncontrolled Digital volume correlation (DVC) eng uncontrolled Image-based finite element simulations Ingenieurwissenschaften und zugeordnete Tätigkeiten 8 Zerstörungsfreie Prüfung 8.5 Röntgenbildgebung Material Degradationsmechanismen Verlagsliteratur Datei für die Öffentlichkeit verfügbar ("Open Access") Wissenschaftliche Artikel der BAM Bundesanstalt für Materialforschung und -prüfung (BAM) https://opus4.kobv.de/opus4-bam/files/63324/Bruson_et_al_Polito_nylon_lattices.pdf