Design and Topology Optimization of Lattice Structures Using Deformable Implicit Surfaces for Additive Manufacturing

2015 ◽  
Author(s):  
Erhan Batuhan Arisoy ◽  
Suraj Musuvathy ◽  
Lucia Mirabella ◽  
Edward Slavin
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Structural Characteristics ◽  
Product Lifecycle Management ◽  
Lattice Structures ◽  
Cad System ◽  
Computer Aided ◽  
Rapid Generation ◽  
Freeform Deformation ◽  
Surface Representations

Additive manufacturing (AM) enables creation of objects with complex internal lattice structures for functional, aesthetic, structural and fabrication considerations. Several approaches for lattice generation and optimization, and their implementations in commercial systems exist. However, these commercial systems are typically independent from a CAD system, and therefore introduces workflow complexities for product lifecycle management. In this paper, we present a unified computer-aided framework for design, computer-aided engineering analysis (CAE) of solids with lattice structures, and freeform topology optimization within the CAD system that enables a seamless workflow. The proposed framework takes as input a solid CAD model and enables rapid generation of different lattice structures as repeated arrangements of lattice template shapes that replace input solid volume. Generated internal patterns are further optimized through freeform modifications to improve structural characteristics of the input model. Lattice modeling and optimization is performed using discrete implicit surface representations for the ease in representing complex topologies and performing modeling and freeform deformation operations. The output of the proposed framework is a polygonal represenatation of the lattified model ready for 3D printing. We have implemented our framework as a plugin to the Siemens PLM NX software system and examples are demonstrated for typical products in aerospace, medical and automotive industries.

Lattice Structure Design for Additive Manufacturing: Unit Cell Topology Optimization

2019 ◽  
Author(s):  
Bradley Hanks ◽  
Mary Frecker
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Lattice Structure ◽  
Optimization Method ◽  
Structure Design ◽  
Unit Cell ◽  
Lattice Structures ◽  
Design For Additive Manufacturing ◽  
Structure Topology

Abstract Additive manufacturing is a developing technology that enhances design freedom at multiple length scales, from the macroscale, or bulk geometry, to the mesoscale, such as lattice structures, and even down to tailored microstructure. At the mesoscale, lattice structures are often used to replace solid sections of material and are typically patterned after generic topologies. The mechanical properties and performance of generic unit cell topologies are being explored by many researchers but there is a lack of development of custom lattice structures, optimized for their application, with considerations for design for additive manufacturing. This work proposes a ground structure topology optimization method for systematic unit cell optimization. Two case studies are presented to demonstrate the approach. Case Study 1 results in a range of unit cell designs that transition from maximum thermal conductivity to minimization of compliance. Case Study 2 shows the opportunity for constitutive matching of the bulk lattice properties to a target constitutive matrix. Future work will include validation of unit cell modeling, testing of optimized solutions, and further development of the approach through expansion to 3D and refinement of objective, penalty, and constraint functions.

scholarly journals Design and Optimization of Lattice Structures: A Review

2020 ◽  
Vol 10 (18) ◽  
pp. 6374
Author(s):  
Chen Pan ◽  
Yafeng Han ◽  
Jiping Lu
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Voronoi Tessellation ◽  
High Strength ◽  
Research Literature ◽  
Main Concern ◽  
Lattice Structures ◽  
Uniform Lattice ◽  
And Topology ◽  
Bio Engineering

Cellular structures consist of foams, honeycombs, and lattices. Lattices have many outstanding properties over foams and honeycombs, such as lightweight, high strength, absorbing energy, and reducing vibration, which has been extensively studied and concerned. Because of excellent properties, lattice structures have been widely used in aviation, bio-engineering, automation, and other industrial fields. In particular, the application of additive manufacturing (AM) technology used for fabricating lattice structures has pushed the development of designing lattice structures to a new stage and made a breakthrough progress. By searching a large number of research literature, the primary work of this paper reviews the lattice structures. First, based on the introductions about lattices of literature, the definition and classification of lattice structures are concluded. Lattice structures are divided into two general categories in this paper: uniform and non-uniform. Second, the performance and application of lattice structures are introduced in detail. In addition, the fabricating methods of lattice structures, i.e., traditional processing and additive manufacturing, are evaluated. Third, for uniform lattice structures, the main concern during design is to develop highly functional unit cells, which in this paper is summarized as three different methods, i.e., geometric unit cell based, mathematical algorithm generated, and topology optimization. Forth, non-uniform lattice structures are reviewed from two aspects of gradient and topology optimization. These methods include Voronoi-tessellation, size gradient method (SGM), size matching and scaling (SMS), and homogenization, optimization, and construction (HOC). Finally, the future development of lattice structures is prospected from different aspects.

A Multi-Scale Topology Optimization Approach for Optimal Macro-Layout and Local Grading of TPMS-Based Lattices

2021 ◽  
Author(s):  
Niclas Strömberg
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Local Density ◽  
Bulk Material ◽  
Transversely Isotropic ◽  
Benchmark Problems ◽  
Optimization Approach ◽  
Lattice Structures ◽  
Efficient Design ◽  
Multi Scale

Abstract The use of lattice structures in design for additive manufacturing has quickly emerged as a popular and efficient design alternative for creating innovative multifunctional lightweight solutions. In particular, the family of triply periodic minimal surfaces (TPMS) studied in detail by Schoen for generating frame-or shell-based lattice structures seems extra promising. In this paper a multi-scale topology optimization approach for optimal macro-layout and local grading of TPMS-based lattice structures is presented. The approach is formulated using two different density fields, one for identifying the macro-layout and another one for setting the local grading of the TPMS-based lattice. The macro density variable is governed by the standard SIMP formulation, but the local one defines the orthotropic elasticity of the element following material interpolation laws derived by numerical homogenization. Such laws are derived for frame- and shell-based Gyroid, G-prime and Schwarz-D lattices using transversely isotropic elasticity for the bulk material. A nice feature of the approach is that the lower and upper additive manufacturing limits on the local density of the TMPS-based lattices are included properly. The performance of the approach is excellent, and this is demonstrated by solving several three-dimensional benchmark problems, e.g., the optimal macro-layout and local grading of Schwarz-D lattice for the established GE-bracket is identified using the presented approach.

Designing of Topology Optimized Parts for Additive Manufacturing

2019 ◽  
Vol 822 ◽  
pp. 526-533
Author(s):  
Alexey Orlov ◽  
Dmitriy V. Masaylo ◽  
Igor A. Polozov ◽  
Pu Guang Ji
Keyword(s):  
Numerical Simulation ◽  
Topology Optimization ◽  
Additive Manufacturing ◽  
Strain State ◽  
New Products ◽  
Optimization Method ◽  
Additive Technologies ◽  
Lattice Structures ◽  
Initial Material ◽  
Topology Optimization Method

Due to the additive manufacturing process concept - layered synthesis of products, it becomes necessary to apply new approaches to the design of parts. One of the main tools that need to operate is numerical simulation, capable, with a skilful approach, to give an engineer an integrated procedure to the development of new products. Numerical modeling, in addition to carrying out strength calculations, includes topology optimization and the creation of lattice structures, through which it is possible to create lightweight products. New design meets requirements of strength characteristics. The use of this tool leads to a reduction in the amount of initial material and as a result - cost saving. In this paper, using the bracket as an example, was used the topology optimization method with subsequent redesign. The paper presents the results of calculations of the stress-strain state of the initial and final structures, allowing estimating the possible reduction in the mass of the product and the amount of consumable material in the manufacture of additive technologies.

scholarly journals CAD TOOLS AND FILE FORMAT PERFORMANCE EVALUATION IN DESIGNING LATTICE STRUCTURES FOR ADDITIVE MANUFACTURING

2018 ◽  
Vol 80 (4) ◽  
Author(s):  
Abdul Hadi Azman ◽  
Frédéric Vignat ◽  
François Villeneuve
Keyword(s):  
Performance Evaluation ◽  
Additive Manufacturing ◽  
Computer Aided Design ◽  
Data Exchange ◽  
Lattice Structure ◽  
Lattice Structures ◽  
File Size ◽  
Element Analysis ◽  
Computer Aided ◽  
Octet Truss

Additive manufacturing has opened the door to the creation of lightweight lattice structures. However, present Computer-Aided Design (CAD) and Computer-Aided Engineering (CAE) software are unsuitable for these types of structures. The objective of this research is to examine the performances of current CAD and CAE software to design lattice structures and to demonstrate their limitations and propose requirements for future developments. A performance evaluation of a case study for lattice structure designs was conducted. The criteria used for the evaluation were CAD human-machine-interface, RAM consumption, data exchange between CAD, CAE and CAM tools and finite element analysis (FEA) duration and file sizes. The CAD tool was incapable of executing a repetition function for octet-truss lattice structures of 150 x 150 x 150 mm dimensions or larger and the software stopped working. For 70 × 70 × 70 mm octet-truss lattice structure, the FEA computation file size reached 36.6 GB. The CAD file size of a 200 x 200 x 200 mm octet-truss lattice structure reached nearly 290 MB. In conclusion, this study exposes the performance inadequacy of current CAD and CAE tools and CAD file formats to design lattice structures for additive manufacturing parts.

scholarly journals Toward the integration of lattice structure-based topology optimization and additive manufacturing for the design of turbomachinery components

2019 ◽  
Vol 11 (8) ◽  
pp. 168781401985978
Author(s):  
Enrico Boccini ◽  
Rocco Furferi ◽  
Lapo Governi ◽  
Enrico Meli ◽  
Alessandro Ridolfi ◽  
...  
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Lattice Structure ◽  
Three Dimensional ◽  
Optimization Method ◽  
Lattice Structures ◽  
Stiffness Properties ◽  
Maximum Stiffness ◽  
Layer Manufacturing ◽  
Innovative Materials

Used in several industrial fields to create innovative designs, topology optimization is a method to design a structure characterized by maximum stiffness properties and reduced weights. By integrating topology optimization with additive layer manufacturing and, at the same time, by using innovative materials such as lattice structures, it is possible to realize complex three-dimensional geometries unthinkable using traditional subtractive techniques. Surprisingly, the extraordinary potential of topology optimization method (especially when coupled with additive manufacturing and lattice structures) has not yet been extensively developed to study rotating machines. Based on the above considerations, the applicability of topology optimization, additive manufacturing, and lattice structures to the fields of turbomachinery and rotordynamics is here explored. Such techniques are applied to a turbine disk to optimize its performance in terms of resonance and mass reduction. The obtained results are quite encouraging since this approach allows improving existing turbomachinery components’ performance when compared with traditional one.

scholarly journals Assessment of Computer-Aided Design Tools for Topology Optimization of Additively Manufactured Automotive Components

2021 ◽  
Vol 11 (22) ◽  
pp. 10980
Author(s):  
Enrico Dalpadulo ◽  
Fabio Pini ◽  
Francesco Leali
Keyword(s):  
Topology Optimization ◽  
Additive Manufacturing ◽  
Computer Aided Design ◽  
Combustion Engine ◽  
Element Model ◽  
Optimization Techniques ◽  
Theory And Practice ◽  
Design Tools ◽  
Computer Aided ◽  
Aided Design

The use of Topology Optimization techniques has seen a great development since the last decade. The principal contributor to this trend is the widespread use of Additive Manufacturing technologies to effectively build complex and performant structures over different settings. Nevertheless, the use of Topology Optimization in Design for Additive Manufacturing processes is not simple and research aims to fill the gap between theory and practice by evolving at the same time both approaches, workflows, and design software that allow their implementation. Since a strong connection between methodologies and tools exists, this work proposes a method to assess computer-aided design tools or platforms. This can be applied to sustain the key phase for selection and adoption of the computer-aided tools in industrial settings embracing Additive Manufacturing. The workflow for Topology Optimization implementation, the structure of the proposed evaluation approach, and its application, are presented to demonstrate effective usability. The automotive case study is the redesign of internal combustion engine piston to benefit of metal Additive Manufacturing based enhanced product performance. A preliminary finite element model is defined and a Topology Optimization based redesign is concurrently set up through four different commercial computer-based platforms. The method accounting for the assessment of required operations for the design optimization is applied to perform the tools selection phase.

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.

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