Lattice Structure Design Advisor for Additive Manufacturing Using Gaussian Process

2017 ◽  
Author(s):  
Tsz Ling Elaine Tang ◽  
Yan Liu ◽  
Da Lu ◽  
Erhan Batuhan Arisoy ◽  
Suraj Musuvathy
Keyword(s):  
Additive Manufacturing ◽  
Structural Properties ◽  
Structural Design ◽  
Lattice Structure ◽  
Structure Design ◽  
Structural Performance ◽  
Design Parameters ◽  
Use Case ◽  
Lattice Structures ◽  
Lattice Design

Additive manufacturing (AM) exemplifies the potential of lattice structures to revolutionize structural design. It enables light weight lattice structures to be produced while maintaining the desirable structural performance. Lattice design can vary in different shapes and dimensions. Obtaining the structural performance of a particular lattice structure design is not a straight-forward process. Significant effort is required to perform mechanical testing experiments or to perform finite element analysis (FEA) to characterize the lattice design. In view of that, a guidance system to determine lattice design parameters based on desired functional performance for a specific lattice type is developed, which can be used in interactive design processes and workflows. Homogenization using FEA experiments is applied to characterize the macroscopic lattice structural properties. Mechanical properties of orthotropic cubic lattice f2ccz are estimated. It follows with a design of experiment study to characterize the effective structural properties of 39 lattices with respect to lattice design parameters (unit cell length and strut diameter). A Gaussian process is applied to develop models relating the lattice design parameter to macroscopic structural properties (forward model), and vice versa (inverse model). Both the forward and inverse models are examined and shown to be capable of modeling the FEA experimental dataset of 39 lattices. To illustrate the potential application of the lattice design advisor framework, a structural design use case including lattice part is presented. In the use case, the lattice structure design advisor is proven to be able to estimate an accurate homogenized material property of arbitrary lattice design parameter. This lattice structure design advisor can simplify and streamline the design, modeling and simulation process of lattice-filled structural designs.

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.

Bayesian Optimization of Energy-Absorbing Lattice Structures for Additive Manufacturing

2020 ◽  
Author(s):  
Nathan Hertlein ◽  
Kumar Vemaganti ◽  
Sam Anand
Keyword(s):  
Finite Element ◽  
Additive Manufacturing ◽  
Optimization Problems ◽  
Lattice Structure ◽  
Structure Design ◽  
Bayesian Optimization ◽  
Fe Model ◽  
Lattice Structures ◽  
Element Analysis ◽  
Overhang Angle

Abstract Additive manufacturing has enabled the production of intricate lattice structures that meet stringent design requirements with minimal mass. While many methods such as lattice-based topology optimization are being developed to design lightweight structures for static loading, there is a need for design tools for achieving dynamic loading requirements. Lattice structures have shown particular promise as low-mass energy absorbers, but the computational expense of nonlinear finite element analysis and the difficulty of obtaining objective gradient information has made their optimization for impact loading particularly challenging. This study proposes a Bayesian optimization framework to determine the lattice structure design that provides the best performance under a specified impact, while managing the structure’s mass. Considering nonlinear effects such as plasticity and strain rate sensitivity, a 2D explicit finite element (FE) model is constructed for two lattice unit cell types under impact, and parameterized with respect to geometric attributes such as height, width, and strut thickness. These parameters are considered design variables in a minimization problem with an objective function that balances part volume with a common injury metric, the head injury criterion (HIC). Penalty values are assigned to designs that fail to absorb the entire impact. Design for additive manufacturing (DFAM) constraints including minimum feature thickness and maximum overhang angle are applied to ensure that the optimal design can be manufactured without subsequent manual refinement or post-processing. The best optimizer hyperparameters are then carried over into larger optimization problems involving lattice structures. Future work could include expanding this framework to allow for lattice structure designs with arbitrary boundaries.

An improved lattice structure design optimization framework considering additive manufacturing constraints

2017 ◽  
Vol 23 (2) ◽  
pp. 305-319 ◽  
Author(s):  
Recep M. Gorguluarslan ◽  
Umesh N. Gandhi ◽  
Yuyang Song ◽  
Seung-Kyum Choi
Keyword(s):  
Additive Manufacturing ◽  
Lattice Structure ◽  
Structure Optimization ◽  
Optimization Methods ◽  
Structure Design ◽  
Second Phase ◽  
Manufacturing Constraints ◽  
Ground Structure ◽  
Content Type ◽  
Optimization Framework

Purpose Methods to optimize lattice structure design, such as ground structure optimization, have been shown to be useful when generating efficient design concepts with complex truss-like cellular structures. Unfortunately, designs suggested by lattice structure optimization methods are often infeasible because the obtained cross-sectional parameter values cannot be fabricated by additive manufacturing (AM) processes, and it is often very difficult to transform a design proposal into one that can be additively designed. This paper aims to propose an improved, two-phase lattice structure optimization framework that considers manufacturing constraints for the AM process. Design/methodology/approach The proposed framework uses a conventional ground structure optimization method in the first phase. In the second phase, the results from the ground structure optimization are modified according to the pre-determined manufacturing constraints using a second optimization procedure. To decrease the computational cost of the optimization process, an efficient gradient-based optimization algorithm, namely, the method of feasible directions (MFDs), is integrated into this framework. The developed framework is applied to three different design examples. The efficacy of the framework is compared to that of existing lattice structure optimization methods. Findings The proposed optimization framework provided designs more efficiently and with better performance than the existing optimization methods. Practical implications The proposed framework can be used effectively for optimizing complex lattice-based structures. Originality/value An improved optimization framework that efficiently considers the AM constraints was reported for the design of lattice-based structures.

LATTICE STRUCTURE OPTIMIZATION WITH ORIENTATION-DEPENDENT MATERIAL PROPERTIES

2021 ◽  
pp. 1-33
Author(s):  
Conner Sharpe ◽  
Carolyn Seepersad
Keyword(s):  
Additive Manufacturing ◽  
Design Process ◽  
Material Properties ◽  
Computational Models ◽  
Lattice Structure ◽  
Lattice Structures ◽  
Performance Improvements ◽  
Structural Applications ◽  
Manufacturing Techniques ◽  
And Performance

Abstract Advances in additive manufacturing techniques have enabled the production of parts with complex internal geometries. However, the layer-based nature of additive processes often results in mechanical properties that vary based on the orientation of the feature relative to the build plane. Lattice structures have been a popular design application for additive manufacturing due to their potential uses in lightweight structural applications. Many recent works have explored the modeling, design, and fabrication challenges that arise in the multiscale setting of lattice structures. However, there remains a significant challenge in bridging the simplified computational models used in the design process and the more complex properties actually realized in fabrication. This work develops a design approach that captures orientation-dependent material properties that have been observed in metal AM processes while remaining suitable for use in an iterative design process. Exemplar problems are utilized to investigate the potential design changes and performance improvements that can be attained by taking the directional dependence of the manufacturing process into account in the design of lattice structures.

Lattice Structure Optimization With Orientation-Dependent Material Properties

2020 ◽  
Author(s):  
Conner Sharpe ◽  
Carolyn Conner Seepersad
Keyword(s):  
Additive Manufacturing ◽  
Design Process ◽  
Material Properties ◽  
Computational Models ◽  
Lattice Structure ◽  
Lattice Structures ◽  
Performance Improvements ◽  
Structural Applications ◽  
Manufacturing Techniques ◽  
And Performance

Abstract Advances in additive manufacturing techniques have enabled the production of parts with complex internal geometries. However, the layer-based nature of additive processes often results in mechanical properties that vary based on the orientation of the feature relative to the build plane. Lattice structures have been a popular design application for additive manufacturing due to their potential uses in lightweight structural applications. Many recent works have explored the modeling, design, and fabrication challenges that arise in the multiscale setting of lattice structures. However, there remains a significant challenge in bridging the simplified computational models used in the design process and the more complex properties actually realized in fabrication. This work develops a design approach that captures orientation-dependent material properties that have been observed in metal AM processes while remaining suitable for use in an iterative design process. Exemplar problems are utilized to investigate the potential design changes and performance improvements that can be attained by taking the directional dependence of the manufacturing process into account in the design of lattice structures.

scholarly journals Design of Shoe Soles Using Lattice Structures Fabricated by Additive Manufacturing

2019 ◽  
Vol 1 (1) ◽  
pp. 719-728 ◽  
Author(s):  
Guoying Dong ◽  
Daniel Tessier ◽  
Yaoyao Fiona Zhao
Keyword(s):  
Additive Manufacturing ◽  
Fused Deposition Modeling ◽  
Lattice Structure ◽  
Lattice Structures ◽  
Compression Tests ◽  
Element Analysis ◽  
Fused Deposition ◽  
Footwear Industry ◽  
Deposition Modeling ◽  
Shoe Soles

AbstractAdditive manufacturing (AM) has enabled great application potential in several major industries. The footwear industry can customize shoe soles fabricated by AM. In this paper, lattice structures are discussed. They are used to design functional shoe soles that can have controllable stiffness. Different topologies such as Diamond, Grid, X shape, and Vintiles are used to generate conformal lattice structures that can fit the curved surface of the shoe sole. Finite element analysis is conducted to investigate stress distribution in different designs. The fused deposition modeling process is used to fabricate the designed shoe soles. Finally, compression tests compare the stiffness of shoe soles with different lattice topologies. It is found that the plantar stress is highly influenced by the lattice topology. From preliminary calculations, it has been found that the shoe sole designed with the Diamond topology can reduce the maximum stress on the foot. The Vintiles lattice structure and the X shape lattice structure are stiffer than the Diamond lattice. The Grid lattice structure buckles in the experiment and is not suitable for the design.

The Analysis and Research on the Reliability of Concrete Pavement

2011 ◽  
Vol 217-218 ◽  
pp. 256-261
Author(s):  
Zhao Qiang Zhang ◽  
Zhong Guo Yang
Keyword(s):  
Reliability Analysis ◽  
Systematic Study ◽  
Structural Design ◽  
Structure Design ◽  
Concrete Pavement ◽  
Pavement Performance ◽  
Design Parameters ◽  
Actual Situation ◽  
Structure Reliability ◽  
Vehicle Load

As the uncertainty of the influencing factors including the vehicle load and road environment and the complexity of road structure design parameters making the structural design of concrete pavement does not match with the actual existing situation, therefore, how to further improve the existing pavement design methods and how to scientifically and reasonably evaluate the reliability of the existing pavement performance have been a hot issue among academics and engineers at home and abroad. This paper analyzes and summarizes results of recent studies on the basis, combining with the actual situation of concrete pavement project, and carries out a more in-depth systematic study on the reliability analysis of concrete pavement. By studying the basic theory of engineering structure reliability, this paper proposes analysis methods of pavement reliability which are appropriate for the characteristics of pavement structure.

Design and Analysis of Lattice Structures for Additive Manufacturing

2016 ◽  
Vol 138 (12) ◽  
Author(s):  
Christiane Beyer ◽  
Dustin Figueroa
Keyword(s):  
Additive Manufacturing ◽  
Lattice Structure ◽  
Cost Savings ◽  
Unit Cell ◽  
Cnc Machining ◽  
Numerical Control ◽  
Full Potential ◽  
Lattice Structures ◽  
Cell Structures ◽  
Bending Load

Additive manufacturing (AM) enables time and cost savings in the product development process. It has great potential in the manufacturing of lighter parts or tools by the embedding of cellular/lattice structures that consume less material while still distributing the necessary strength. Less weight and less material consumption can lead to enormous energy and cost savings. Although AM has come a long way over the past 25–30 years since the first technology was invented, the design of parts and tools that capitalize on the technology do not yet encompass its full potential. Designing for AM requires departing from traditional design guidelines and adopting new design considerations and thought structures. Where previous manufacturing techniques (computer numerical control (CNC) machining, casting, etc.) often necessitated solid parts, AM allows for complex parts with cellular and lattice structure implementation. The lattice structure geometry can be manipulated to deliver the level of performance required of the part. The development and research of different cell and lattice structures for lightweight design is of significant interest for realizing the full potential of AM technologies. The research not only includes analysis of existing software tools to design and optimize cell structures, but it also involves design consideration of different unit cell structures. This paper gives a solid foundation of an experimental analysis of additive manufactured parts with diverse unit cell structures in compression and flexural tests. Although the research also includes theoretical finite element analysis (FEA) of the models, the results are not considered here. As an introduction, the paper briefly explains the basics of stress and strain relationship and summarizes the test procedure and methods. The tests concentrate primarily on the analysis of 3D printed polymer parts manufactured using PolyJet technology. The results show the behavior of test specimens with different cell structures under compression and bending load. However, the research has been extended and is still ongoing with an analysis of selective laser melted test specimens in aluminum alloy AlSi10Mg.

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