Design for Manufacturing and Realisation of Architected Porosity through TPMS Gyroids for Load Bearing Selective Laser Melted 316L Stainless Steel

3D printing creates complex, porous metallic structures significant in medical, aerospace, defense, and other engineering applications. Metal 3D printing techniques like selective laser melting (SLM) manage energy density to produce porous parts, but often result in microstructural defects compromising fatigue life. This study explores design-controlled porosity approach in 3D printed stainless steel using gyroid structures architected with 5 to 15% of porosity. SLM was used for manufacturing, and porosity was measured via fluid saturation, gas pycnometer, and micrographic analysis. The study achieved target porosities and approximately 83% geometrical accuracy, highlighting effective design and manufacturing capability with specified porosity.