Geometry-Compliant Lattice Structures Without Cell Truncation
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Solution Overview
Problem
Additive manufacturing of lattice structures often results in structural weaknesses and stress concentrations due to truncation of cellular components to match complex part shapes, complicating the manufacturing process with unwanted artifacts in computer models.
Innovation Solution
A computer modeling and additive manufacturing system that generates a shape-conforming lattice structure by deforming a finite element mesh to match the part's overall shape, ensuring cellular periodicity and independent mesh elements for parallel processing and reduced-order modeling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If lattice structures are truncated to match complex part shapes, then the lattice structure conforms to the part shape, but structural weaknesses and stress concentrations are introduced
Solution Approach 1:
The patent applies local quality by allowing different regions of the lattice structure to have different cellular configurations. Instead of uniformly truncating all cellular components, the system selectively modifies only those components that intersect with the part boundary, while preserving the integrity of internal cellular components. This localized approach maintains structural strength in critical areas while achieving shape conformity at the boundaries.
Solution Approach 2:
The patent inverts the conventional approach by not truncating the lattice to fit the shape, but rather deforming the lattice cells to conform to the shape while maintaining their structural integrity. Instead of cutting away cellular components, the system transforms them through controlled deformation to match the part geometry, thereby avoiding stress concentrations that would result from abrupt truncation.
2Shape
If cellular components are cropped to fit part shapes, then shape conformity is achieved, but unwanted artifacts are introduced in the computer model
Solution Approach 1:
The patent applies preliminary action by performing shape conformity operations during the lattice generation phase rather than as a post-processing step. The finite element mesh is deformed to match the part shape before the lattice structure is constructed, ensuring that all cellular components are properly formed from the outset. This prevents the creation of artifacts that would require subsequent correction and simplifies the overall modeling process.
3Ease of manufacture
If non-conforming lattice structures are used, then manufacturing is simpler, but structural rigidity is reduced
Solution Approach 1:
The patent applies parameter changes by systematically varying the deformation parameters of the finite element mesh to achieve shape conformity. By controlling mesh deformation parameters and lattice cell transformation parameters, the system maintains structural rigidity through optimized cellular configurations while adapting to complex part geometries. This parametric approach enables automated generation of structurally optimal lattice structures for any given part shape.
Data Source
AI summary
A system and method of creating a shape-conforming lattice structure for a part formed via additive manufacturing. The method includes receiving a computer model of the part and generating a finite element mesh. A lattice structure including a number of lattice cellular components may also be generated. Some of the mesh elements of the finite element mesh may be deformed so that the finite element mesh conforms to the overall shape of the part. The lattice structure may then be deformed so that the lattice structure has a cellular periodicity corresponding to the finite elements of the finite element mesh. In this way, the part retains the benefits of its overall shape and the benefits of lattice features without introducing structural weak points, directional stresses, and other structural deficiencies.