Optimization design of variable density lattice structure for additive manufacturing

Energy ◽  
2021 ◽  
pp. 122554
Author(s):  
Xinju Zhang ◽  
Zhanpu Xue ◽  
Quntao Cheng ◽  
Yunguang Ji
Keyword(s):  
Additive Manufacturing ◽  
Optimization Design ◽  
Lattice Structure ◽  
Variable Density

Optimum design of automobile components using lattice structures for additive manufacturing

2020 ◽  
Vol 62 (6) ◽  
pp. 633-639 ◽  
Author(s):  
Büşra Aslan ◽  
Ali Rıza Yıldız
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Optimization Design ◽  
Lattice Structure ◽  
Structure Optimization ◽  
The Finite Element Method ◽  
Special Effect ◽  
Design Structure ◽  
Complex Models ◽  
Automobile Components

Abstract In today’s world, reducing fuel consumption is one of the most important goals for the automotive industry. For this reason, weight reduction is one of the main topics in this research and for various companies. In this research, topology optimization was conducted on a suspension arm as a means of ensuring balance in automobiles. Subsequently, the model, formed by topology optimization was filled with a lattice structure and re-optimized by size optimization to obtain optimum dimensions for the model. These operations are described as lattice structure optimization. Additive manufacturing (3D printer) is necessary to produce complex models (after topology and lattice structure optimization). A static analysis of the new models was conducted by using the finite element method, and the results were compared with those of the initial design of the model. As a result of the comparison, positive results were obtained, and it was shown that topology optimization and lattice structural optimization could be used in the design of vehicle elements. According to the results obtained from lattice structure optimization, design structure can be formed more reliably than via topology optimization. In addition, both configurations and layouts of the cellular structures have a special effect on the overall performance of the lattice structure.

scholarly journals Design of Variable-Density Structures for Additive Manufacturing Using Gyroid Lattices

2017 ◽  
Author(s):  
Botao Zhang ◽  
Kunal Mhapsekar ◽  
Sam Anand
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Volume Fraction ◽  
Complex Geometry ◽  
Lattice Structure ◽  
Variable Density ◽  
Light Weight ◽  
Lattice Structures ◽  
Density Mapping ◽  
Usage Cost

Additive manufacturing (AM) processes enable the creation of lattice structures having complex geometry which offer great potential for designing light weight parts. The combination of AM and cellular lattice structures provide promising design solutions in terms of material usage, cost and part weight. However, the geometric complexity of the structures calls for a robust methodology to incorporate the lattices in parts designs and create optimum light weight designs. This paper proposes a novel method for designing light weight variable-density lattice structures using gyroids. The parametric 3D implicit function of gyroids has been used to control the shape and volume fraction of the lattice. The proposed method is then combined with the density distribution information from topology optimization algorithm. A density mapping and interpolation approach is proposed to map the output of topology optimization into the parametric gyroids structures which results in an optimum lightweight lattice structure with uniformly varying densities across the design space. The proposed methodology has been validated with two test cases.

scholarly journals A Kind of Filling Lattice Structure Based on DFAM for Mechanical Parts: The Diamond Lattice Structure

2021 ◽  
Vol 2021 ◽  
pp. 1-14
Author(s):  
Xuan Yin ◽  
Wenjun Meng ◽  
Jinzhao Cheng ◽  
Hailong Wang ◽  
Xiaoxia Zhao
Keyword(s):  
Mathematical Model ◽  
Additive Manufacturing ◽  
Lattice Structure ◽  
Variable Density ◽  
Diamond Lattice ◽  
Compression Tests ◽  
Compression Performance ◽  
Mechanical Parts ◽  
Equivalent Modulus ◽  
The Mathematical Model

Thanks to the geometric and material complexity of additive manufacturing, the design space of mechanical parts has been developed, in which lattice filling structure customization can be applied to the solid filling of mechanical parts to achieve the goal of mechanical structure lightweight. A kind of diamond lattice structure unit is designed by imitating the natural method based on Design for Additive Manufacturing of mechanical parts. The mathematical model of the relative density and mechanical properties of the unit are established, and the relationship between the two is obtained, which is verified by simulations; then the relatively uniform results are obtained. The variable density hypothesis of diamond lattice structure is proposed, the methods of simulations and compression tests are used to verify the hypothesis, and the results show that the variable density structure with the density of the filling element decreasing gradually with the stress point as the center has better compression performance and concurrently verify the correctness and applicability of the equivalent modulus of elasticity mathematical model. The results of this study can be applied to the solid sandwich filling of pressure mechanical parts, and the stress density matching relationship can be carried out to further specific design.

A Novel Optimization Design Method of Additive Manufacturing Oriented Porous Structures

2018 ◽  
Author(s):  
Jiaqi Zhao ◽  
Ming Zhang ◽  
Yu Zhu ◽  
Xin Li ◽  
Leijie Wang
Keyword(s):  
Additive Manufacturing ◽  
Porous Structure ◽  
Optimization Design ◽  
Design Method ◽  
Variable Density ◽  
Structural Performance ◽  
Porous Structures ◽  
Density Filter ◽  
Advanced Development ◽  
Design For Am

The advanced development of additive manufacturing (AM) has greatly promoted the research and application of variable density porous structures. Meanwhile, AM constraints highlight the significance of design for AM (DFAM). The structural performance of existing topology optimization (TO) based design methods is limited and AM constraints are little considered. In this paper, we propose a novel optimization design method of AM oriented porous structures which allows the existence of void. A novel density filter is designed to achieve multi-interval TO for better structural performance and satisfy the minimum feature size constraint. Meanwhile, another customized density filter is designed to obtained support-free porous structure for the buildability constraint of AM. FEA results demonstrate that optimized porous structure designed by proposed method has better stiffness performance and adaptability to AM constraints, compared with existing methods.

Design Tool for Topology Optimization of Self Supporting Variable Density Lattice Structures for Additive Manufacturing

2021 ◽  
pp. 1-36
Author(s):  
Matthew McConaha ◽  
Vysakh Venugopal ◽  
Sam Anand
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Lattice Structure ◽  
Variable Density ◽  
Design Tool ◽  
Lattice Structures ◽  
Interpolation Scheme ◽  
Void Space ◽  
Lattice Density ◽  
Optimization Methodology

Abstract Additive manufacturing (AM) allows for the inclusion of complicated geometric features that are impractical or impossible to manufacture by other means. Among such features is the collection of intricate and periodic strut-like geometries known as lattice structures. Lattice structures are desirable for their ability to provide stiffness through a large number of supporting members while employing void space within the geometry as a means to reduce part material volume. Strut thicknesses of every lattice in a part are generally not well optimized in order to maximize part stiffness, and often every lattice unit cell is identical throughout the part. This work presents a lattice density optimization methodology able to find the optimal graded lattice density distribution for maximizing the part stiffness and also improving the additive manufacturability of the part. The material property interpolation scheme used in SIMP optimization is replaced by a representative volume element (RVE)-based interpolation scheme that more accurately captures the material properties of the prescribed lattice structure at an arbitrary density. A filter has been developed that allows for the trimming of unnecessary lattices while simultaneously ensuring that the geometry remains self-supporting during the AM build process. This filter is incorporated seamlessly within the topology optimization routine. This increases the optimality of the resulting design compared to full-domain lattice filling and increases the viability of the design from a manufacturing standpoint compared to unconstrained lattice trimming.

scholarly journals Lattice structure lightweight triangulation for additive manufacturing

2017 ◽  
Vol 90 ◽  
pp. 95-104 ◽  
Author(s):  
Laurent Chougrani ◽  
Jean-Philippe Pernot ◽  
Philippe Véron ◽  
Stéphane Abed
Keyword(s):  
Additive Manufacturing ◽  
Lattice Structure

Redesign of the Femoral Stem for a Total Hip Arthroplasty for Additive Manufacturing

2018 ◽  
Author(s):  
Bradley Hanks ◽  
Shantanab Dinda ◽  
Sanjay Joshi
Keyword(s):  
Additive Manufacturing ◽  
Total Hip Arthroplasty ◽  
Hip Arthroplasty ◽  
Lattice Structure ◽  
Stress Shielding ◽  
Patient Specific ◽  
Hip Implants ◽  
Hip Implant ◽  
Total Hip ◽  
Multiple Materials

Total hip arthroplasty (THA) is an increasingly common procedure that replaces all or part of the hip joint. The average age of patients is decreasing, which in turn increases the need for more durable implants. Revisions in hip implants are frequently caused by three primary issues: femoral loading, poor fixation, and stress shielding. First, as the age of hip implant patients decreases, the hip implants are seeing increased loading, beyond what they were traditionally designed for. Second, traditional implants may have roughened surfaces but are not fully porous which would allow bone to grow in and through the implant. Third, traditional implants are too stiff, causing more load to be carried by the implant and shielding the bone from stress. Ultimately this stress shielding leads to bone resorption and implant loosening. Additive manufacturing (AM) presents a unique opportunity for enhanced performance by allowing for personalized medicine and increased functionality through geometrically complex parts. Much research has been devoted to how AM can be used to improve surgical implants through lattice structures. To date, the authors have found no studies that have performed a complete 3D lattice structure optimization in patient specific anatomy. This paper discusses the general design of an AM hip implant that is personalized for patient specific anatomy and proposes a workflow for optimizing a lattice structure within the implant. Using this design workflow, several lattice structured AM hip implants of various unit cell types are optimized. A solid hip implant is compared against the optimized hip implants. It appears the AM hip implant with a tetra lattice outperforms the other implant by reducing stiffness and allowing for greater bone ingrowth. Ultimately it was found that AM software still has many limitations associated with attempting complex optimizations with multiple materials in patient specific anatomy. Though software limitations prevented a full 3D optimization in patient specific anatomy, the challenges associated such an approach and limitations of the current software are discussed.

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