3D Meta-Structure Workpieces With Stress-Optimized Lattice Mesh
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current additive manufacturing technologies lack efficient methods for designing mechanical systems with optimized stress/strain three-dimensional meta-structure structures that can maintain strength while reducing unnecessary material, particularly in load-bearing components.
Innovation Solution
A computer-implemented method generates three-dimensional meta-structure models using finite element mesh structures with varying cross-sectional areas and interlinking linkages, forming tetrahedral, hexahedral, and fractal elements, which can be iteratively refined to produce ultra-lightweight components with programmable density and porosity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional solid structures are used in additive manufacturing, then strength is maintained, but weight and material usage increase significantly
Solution Approach 1:
The patent divides solid structures into discrete lattice units (e.g., octet truss elements, tetrahedral cells) that are assembled into larger meta-structures. This segmentation allows strength to be distributed through the lattice geometry while removing unnecessary material, achieving weight reduction while maintaining structural integrity through the modular unit design
Solution Approach 2:
The patent applies different lattice configurations, densities, and material properties to different regions of the component based on local stress requirements. High-stress areas receive denser or stronger lattice structures while low-stress areas use sparser configurations, optimizing the strength-to-weight ratio throughout the entire component
2Weight of moving object
If material is removed to reduce weight, then weight decreases, but structural strength may be compromised
Solution Approach 1:
The patent employs porous lattice structures with controlled porosity ratios (typically 30-70% void space) that maintain strength through the geometric arrangement of struts and nodes. The lattice architecture provides load-bearing pathways while the porous structure reduces material usage and weight, achieving both goals simultaneously through optimized cell geometry and density distribution
3Strength
If complex meta-structures are designed for optimization, then structural efficiency improves, but manufacturing complexity and design time increase
Solution Approach 1:
The patent develops universal lattice unit libraries (e.g., octet truss, body-centered cubic, face-centered cubic) that can be applied across different component types and loading conditions. These standardized units provide proven structural efficiency while simplifying the design process, as engineers can select from pre-validated configurations rather than designing custom lattices from scratch
Solution Approach 2:
The patent utilizes parametric design approaches where lattice geometry, density, orientation, and material properties can be adjusted through parameter modification rather than complete redesign. This allows optimization of structural efficiency while maintaining design simplicity, as changes are made through parameter tuning of existing lattice configurations rather than creating entirely new structures
4Ease of manufacture
If uniform lattice structures are used, then manufacturing is simplified, but localized stress optimization is limited
Solution Approach 1:
The patent implements spatially varying lattice properties where different lattice types, densities, and orientations are assigned to different regions based on stress analysis. This allows localized optimization of strength and stiffness where needed while maintaining relatively simple manufacturing processes through automated generation and additive manufacturing capabilities
Data Source
AI summary
The exemplified methods and systems facilitate manufacturing of a new class of mechanical, loading-bearing components having optimized stress/strain three-dimensional meta-structure structures (also referred to herein as “Meshagons”) as finite-element-based 3D volumetric mesh structures. The resulting three-dimensional meta-structure structures provide high strength, ultra-light connectivity, with programmable interlinkage properties (e.g., density/porosity of linkages).