Graded Cellular Structures via Additive Manufacturing
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Solution Overview
Problem
Conventional manufacturing techniques are ill-suited for creating graded cellular structures with tailored combinations of static and dynamic properties, particularly with material extrusion AM methods like FDM, FFF, BAAM, robocasting, and DIW, which struggle to achieve non-uniform cellular arrangements and varying cell geometries across a structure.
Innovation Solution
A method involving additive manufacturing that controls the dispensing of feedstock material to form layers with non-uniform relative densities and cell geometries using shift functions, allowing for the creation of graded cellular structures with varying cell sizes, shapes, and wall thicknesses across the width and height of the structure, employing techniques such as fused deposition modeling, fused filament fabrication, big area additive manufacturing, robocasting, and direct ink writing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional manufacturing techniques are used, then manufacturing simplicity is maintained, but the ability to create graded cellular structures with non-uniform cellular arrangements and varying cell geometries is lost
Solution Approach 1:
The patent applies local quality by varying cell geometry parameters (such as wall thickness, cell size, and shape) at different locations within the structure. The method uses spatially varying design parameters to create regions with different relative densities and mechanical properties, allowing each part of the structure to have optimized local characteristics suited to its functional requirements.
Solution Approach 2:
The patent employs dynamics by implementing continuous or stepped gradients in cellular structure parameters throughout the component. Rather than static uniform geometry, the structure transitions dynamically in its properties from one region to another, enabling smooth variation in mechanical behavior, density, and functional performance across the component volume.
2Adaptability or versatility
If a fixed unit cell geometry is used, then manufacturing process simplicity is maintained, but the range of properties that can be achieved within a structure is drastically limited
Solution Approach 1:
The patent applies parameter changes by systematically varying geometric parameters of the unit cells (such as wall thickness, cell edge length, shape factors) as functions of spatial coordinates. This allows continuous adjustment of structural properties like relative density, stiffness, and strength without changing the fundamental cellular topology, thereby expanding the achievable property range while maintaining manufacturing feasibility.
3Adaptability or versatility
If uniform cellular distribution is used, then manufacturing simplicity is maintained, but tailored mechanical and functional properties spatially within a component cannot be achieved
Solution Approach 1:
The patent applies segmentation by dividing the component into multiple regions or layers, each with distinct cellular parameter specifications. The manufacturing process sequentially deposits material with varying geometric parameters for each region, enabling precise spatial control over mechanical and functional properties while breaking down the complex graded structure into manageable manufacturing segments.
Data Source
AI summary
A method of producing a cellular structure via an additive manufacturing technique includes the steps of: providing a feedstock material to an additive manufacturing printer device; dispensing the feedstock material from the printer device; and controlling the dispensing of the feedstock material to form at least one layer of the cellular structure according to a first predetermined gradient. In some aspects, the cellular structure comprises an array of cells surrounded, respectively, by walls, and arranged to create a non-uniform relative density and/or cell geometry across a width and/or a height of the cellular structure. An article of manufacture produced by such methods includes a cellular structure configured to produce a controlled collapse with selectable dynamic stiffness characteristics by altering the distribution and geometry of cells within the cellular structure, while being able to maintain a substantially similar static stiffness characteristic.