Dual Lattice Modeling for Crash Simulation and Manufacturing
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Solution Overview
Problem
Existing CAD software struggles to efficiently design and manufacture lattice structures that can withstand dynamic events like car crashes or helmet impacts, as they lack a comprehensive dual representation for both design and simulation purposes.
Innovation Solution
The implementation of a dual lattice representation that combines a boundary representation (B-Rep) model with a finite element analysis (FEA) representation, allowing for both redesign of lattice structures within CAD programs and accurate dynamic simulation of their behavior during crashes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a boundary representation (B-Rep) model is used for lattice structure design in CAD software, then design precision and ease of manipulation are improved, but the ability to perform accurate dynamic crash simulation deteriorates
Solution Approach 1:
The lattice structure model is segmented into two distinct representations: a B-Rep model for design and manufacturing operations, and a Finite Element Analysis (FEA) model for simulation. Each representation serves its specific purpose optimally, with the B-Rep maintaining geometric precision for CAD operations and the FEA providing accurate structural response data for crash simulation.
Solution Approach 2:
A dual representation system acts as an intermediary between design and simulation domains. The system maintains both B-Rep and FEA models simultaneously, allowing seamless transition between design precision requirements and simulation accuracy requirements without compromising either aspect.
2Reliability
If a detailed FEA model is used for crash simulation, then simulation accuracy is improved, but computational work and processing time increase
Solution Approach 1:
The FEA model is prepared in advance as part of the dual representation system, with meshing and element definition completed during the design phase. This preliminary preparation allows the simulation to proceed more efficiently when needed, as the computational infrastructure is already in place and optimized.
3Strength
If lattice structures are redesigned to withstand dynamic events, then strength and reliability are improved, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The dual representation system serves multiple functions simultaneously: it enables design visualization, performs structural simulation, guides manufacturing preparation, and facilitates iterative optimization. This multi-functionality reduces the need for separate systems and simplifies the overall design-to-manufacturing workflow despite the complexity of the lattice structures.
Data Source
AI summary
Methods, systems, and apparatus, including medium-encoded computer program products, for designing and manufacturing physical objects including lattice structures include, in one aspect, a method including: providing a three-dimensional model including a dual representation of a lattice structure, wherein both a shell mesh model and a solid body model of the lattice structure are producible from an additional model of the lattice structure, and beams of the lattice structure in the solid body model are hollow; performing numerical simulation using at least the shell mesh model of the dual representation to produce a current numerical assessment; modifying the additional model of the dual representation based on the current numerical assessment; repeating the performing and the modifying one or more times until the numerical simulation indicates the lattice structure satisfies at least one response requirement; and providing at least the solid body model for use in manufacturing the lattice structure.