Conformal Lattice Structures for Curved Tubular Fluid Paths

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Solution Overview

Problem

Conventional internal formations in tubular structures do not conform to the curvature of the enclosing structures, leading to inhibited fluid flow, undesirable flow characteristics, and structural weaknesses such as fluid hammer and cavitation, as well as inefficient structural properties.

Innovation Solution

A computer modeling and additive manufacturing system that generates a lattice structure conforming to the curvature of tubular structures by creating a finite element mesh and modifying a lattice cellular component to follow the inner surface of the tubular structure, using additive manufacturing to deposit material layer by layer.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If conventional internal formations are used in tubular structures, then structural support is provided, but fluid flow is inhibited and structural weak points are introduced at curved sections

Engineering Contradiction:

Improvestructural supportVSAvoidfluid flow continuity

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The lattice structure's unit cells are locally oriented to align with the curvature of the tubular structure at different locations. The orientation of lattice elements varies continuously or discretely to match the local geometry, ensuring that the structure provides support while maintaining smooth fluid flow paths without structural weak points at curved sections.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The lattice structure is designed to follow and conform to the curved geometry of the tubular structure. The unit cells are arranged and oriented to match the curvature, creating a seamless integration that eliminates discontinuities and structural weak points typically found at curved sections where conventional internal formations would intersect the curvature.

Inventive Principle:

Principle #14Spheroidality (Curvature)

2Ease of manufacture

If internal formations do not conform to tubular structure curvature, then manufacturing is simplified, but fluid flow characteristics deteriorate with fluid hammer and cavitation

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidfluid hammer and cavitation

Core Design Contradiction:

Ease of manufactureVSObject-generated harmful factors

Solution Approach 1:

The orientation parameters of the lattice unit cells are changed to align with the local curvature of the tubular structure. By varying the orientation angles and directions of lattice elements according to the curvature profile, the structure achieves conformal geometry that guides fluid flow smoothly around curves, preventing fluid hammer and cavitation while remaining manufacturable through additive processes.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The lattice structure employs dynamic orientation of unit cells that adapts to the changing curvature along the tubular structure. Rather than using fixed orthogonal orientations, the lattice elements are positioned and angled to follow the dynamic geometry of the curve, creating continuous flow paths that accommodate the varying curvature without creating harmful flow separation or pressure shocks.

Inventive Principle:

Principle #15Dynamics

3Device complexity

If conventional internal formations are used, then device complexity is reduced, but structural integrity at curved sections is compromised

Engineering Contradiction:

Improveformation geometryVSAvoidstructural integrity at curves

Core Design Contradiction:

Device complexityVSStrength

Solution Approach 1:

The internal formation is segmented into multiple lattice unit cells that can be independently oriented and positioned. This segmentation allows each unit cell to be tailored to the local curvature requirements, with orientation parameters adjusted for each segment. The modular nature of the lattice structure enables complex curved geometries to be constructed from simple repeating units, maintaining manufacturability while achieving superior structural integrity at curved sections.

Inventive Principle:

Principle #1Segmentation

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The lattice structure guides fluid flow without restriction, reduces structural weaknesses, and maintains consistent flow paths, thereby minimizing fluid hammer and cavitation while enhancing structural integrity.

Implementation Method 1

The additive manufacturing system is configured to produce the lattice structure via additive manufacturing material deposited layer by layer according to the lattice structure

Methodology Applied

Scientific EffectAdditive manufacturing: 3D Printing

Data Source

PatentUS12427721B2System, method, and computer program for creating an internal conforming structure

Publication Date: 2025.09.30 HONEYWELL FEDERAL MANUFACTURING & TECHNOLOGIES LLC

AI summary

A system for creating an internal formation of a tubular structure having an inner surface via additive manufacturing. The system broadly includes a computer modeling system and an additive manufacturing system. The computer modeling system may include a processor for generating a lattice cellular component via computer-aided design software according to inputs received from a user. The processor may also generate an internal formation lattice structure based on the lattice cellular component and modify the lattice structure to follow and/or conform to the curvature of the inner surface of the outer wall of the tubular structure. The additive manufacturing system may be configured to produce the lattice structure and the tubular structure via additive manufacturing material deposited layer by layer according to the lattice structure.