Lattice Cell Transitioning for Additive Manufacturing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing lattice design methods struggle to smoothly transition between different primary lattice unit cells, especially when specific mechanical or tensile properties are required in adjacent regions, as direct transitions often involve intermediate cells with unsatisfactory properties.
Innovation Solution
A method for creating three-dimensional lattice objects with multiple zones of different lattice unit cells that smoothly transition through a series of intermediate unit cells, where primary unit cells are defined by a universal unit cell, allowing struts to gradually change length and merge to form a single strut, enabling seamless transitions between zones.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If direct transitions between different primary lattice unit cells are used, then the structure is simpler, but the mechanical properties in adjacent regions become unsatisfactory due to disconnects or rough transitions
Solution Approach 1:
The patent introduces intermediate lattice unit cells as mediators between different primary lattice unit cells. These intermediate cells serve as transition structures that bridge the gap between adjacent zones with different mechanical properties, ensuring smooth transitions and continuous mechanical performance without disconnects or rough transitions.
Solution Approach 2:
The patent employs a series of intermediate unit cells where parameters such as strut length, cell size, and geometric configuration gradually change from one primary lattice type to another. This progressive parameter variation enables seamless transitions while maintaining structural integrity and continuous mechanical properties across zone boundaries.
2Reliability
If a series of intermediate unit cells is used to transition between primary lattice unit cells, then the transition between zones becomes smooth and continuous, but the structural complexity increases
Solution Approach 1:
The patent segments the transition zone into multiple discrete intermediate lattice unit cells arranged in a series. Each intermediate cell is designed with specific geometric characteristics that progressively bridge the gap between different primary lattice types, enabling smooth transitions while managing structural complexity through systematic segmentation.
Solution Approach 2:
The patent develops a universal set of intermediate lattice unit cells that can transition between multiple different primary lattice types. These intermediate cells serve multiple functions: they bridge structural gaps, maintain mechanical continuity, and accommodate various lattice configurations, thereby reducing overall design complexity despite the increased number of cell types.
3Strength
If different lattice unit cells are used in adjacent zones to meet specific mechanical or tensile property requirements, then the mechanical performance is optimized, but the transition between zones becomes disconnected or rough
Solution Approach 1:
The patent introduces intermediate lattice unit cells as mediator structures between adjacent zones with different mechanical requirements. These intermediate cells gradually transition the structural characteristics from one zone to another, ensuring that the mechanical properties optimize locally while maintaining overall compositional stability and smooth zone transitions without disconnects or rough transitions.
Data Source
AI summary
Three-dimensional (3D) lattice objects with multiple zones of different lattice unit cells may be formed by additive manufacturing. Sets of primary unit cells are provided such that cach primary unit cell is configured to smoothly transition to other primary unit cells through a series of intermediate unit cells. A universal unit cell may define the primary and intermediate unit cells.