Additive Manufacturing Infill Geometry Generation
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Solution Overview
Problem
Conventional additive manufacturing of sandwich panels results in irregular and inconsistent topology at infill/face sheet interfaces, leading to manufacturing challenges and high stress concentrations, as well as difficulties in removing loose powder due to entrapped powder in unit cell structures.
Innovation Solution
A method and system for generating a panel infill geometry using a driver mesh and reference unit cell mesh, which are mapped onto hexahedral elements using basis functions, resulting in a consistent topology and facilitating the removal of loose powder by creating interconnected pathways within the unit cell structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional prior art infill geometry with orthogonally-repeating structural pattern is used, then the additive manufacturing process can be completed, but irregular and inconsistent topology is created at the infill/face sheet interfaces resulting in manufacturing challenges and high stress concentrations
Solution Approach 1:
The patent applies local quality by making the unit cell geometry adaptive to local conditions. The mapping process adjusts the size and shape of each unit cell based on the underlying hexahedral mesh elements, allowing the infill structure to conform locally to the face sheet geometry and panel curvature, thereby achieving consistent topology at interfaces while reducing stress concentrations
Solution Approach 2:
The patent changes geometric parameters of the unit cell structures through the mapping process. By transforming a reference unit cell mesh onto hexahedral elements using basis functions, the patent dynamically adjusts unit cell dimensions, orientations, and shapes to achieve consistent footprint patterns at infill/face sheet interfaces while maintaining structural integrity
2Ease of manufacture
If conventional unit cell structures with enclosed geometry are used, then the inner core structure is formed, but loose powder becomes entrapped and cannot be removed after additive manufacturing
Solution Approach 1:
The patent applies porous material principles by designing unit cell geometries with intentional void spaces and interconnected pathways. The mapping process creates a structured porous infill pattern that allows loose powder to escape through the structure during and after manufacturing, eliminating powder entrapment while maintaining structural functionality
Solution Approach 2:
The patent segments the inner core into discrete unit cell structures with controlled geometries. By dividing the infill into separable unit cells with specific configurations, the patent creates pathways for powder removal while maintaining the overall structural integrity of the panel
3Adaptability or versatility
If irregularly shaped panels with curvature are manufactured using conventional infill geometry, then the panel shape is achieved, but the unit cell structures do not conform well resulting in manufacturing challenges
Solution Approach 1:
The patent applies dynamics by making the unit cell geometry adaptive and flexible. The mapping process dynamically adjusts unit cell size, shape, and orientation based on the local geometry of the panel and face sheets, allowing the infill structure to conform to irregular shapes and curvatures while maintaining consistent interfaces
Solution Approach 2:
The patent uses dimensionality change by mapping from a reference configuration space to the actual panel geometry space. By using basis functions defined on quadrilateral elements to transform reference unit cells onto hexahedral elements, the patent accommodates complex three-dimensional panel shapes including curvature in one or two directions while maintaining interface consistency
Data Source
AI summary
A method of generating a panel infill geometry of a sandwich panel includes providing a driver mesh comprised of quadrilateral elements. The method additionally includes providing a reference unit cell mesh having a unit cell geometry configured to fit exactly within a unit cube. The unit cell geometry comprises a hollow center portion, centered on a cube center, and closed except for 8 openings respectively located proximate 8 corners of the unit cube. The method further includes mapping the reference unit cell meshes respectively onto a plurality of hexahedral elements respectively associated with the plurality of quadrilateral elements, through the use of basis functions defined on each of the plurality of quadrilateral elements in a manner causing adjustment of the size and shape of the plurality of reference unit cell meshes to conform respectively to the plurality of hexahedral elements.