Dual Lattice Representation for Crash Simulation and Hollow Beams
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Solution Overview
Problem
Current CAD software lacks the capability to efficiently design and simulate lattice structures for dynamic events like car crashes or helmet impacts, as they often rely on static simulations and are not optimized for additive manufacturing, leading to inefficiencies in design cycles and material usage.
Innovation Solution
A dual representation of lattice structures using T-Splines and FEA models that enable dynamic simulation and optimization, allowing for both CAD modeling and additive manufacturing, with automated workflows that offload generative design to the cloud, facilitating the creation of hollow lattice structures for improved impact response.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If static simulation methods are used in current CAD software, then design simplicity is maintained, but dynamic crash simulation capability is insufficient
Solution Approach 1:
The system segments the simulation capability into two distinct representations: a B-Rep model for CAD design and a shell mesh FEA model for dynamic crash simulation. This segmentation allows each representation to be optimized for its specific purpose while working together through automated conversion processes, resolving the contradiction between simulation reliability and system complexity.
Solution Approach 2:
The patent introduces an intermediary automated workflow that converts B-Rep lattice models into shell mesh FEA models. This intermediary process enables dynamic crash simulation without requiring users to manually create complex FEA models, thus improving simulation capability while keeping the user interface simple.
2Productivity
If traditional B-Rep modeling is used for lattice structures, then manufacturing precision is improved, but computational efficiency for dynamic simulation is reduced
Solution Approach 1:
The system implements dynamic model adaptation by automatically converting static B-Rep lattice models into shell mesh FEA models optimized for dynamic simulation. The shell mesh representation dynamically adjusts the computational model based on the simulation requirements, improving computational efficiency while preserving the geometric precision of the original B-Rep design through automated conversion.
3Loss of substance
If solid lattice structures are manufactured, then structural strength is maximized, but material usage efficiency is reduced
Solution Approach 1:
The patent employs porous lattice structures with hollow beams instead of solid structures. The shell mesh FEA model accurately represents these hollow beams, enabling optimization of material distribution. This approach maintains structural strength by concentrating material where needed while reducing overall material usage through the porous lattice architecture.
Solution Approach 2:
The system enables parametric design of lattice structures where beam thickness, cell size, and material distribution can be optimized. By changing these parameters in the B-Rep model and automatically converting to shell mesh for simulation, the system finds optimal balances between material usage and structural strength.
4Productivity
If manual design iteration is performed, then design flexibility is maintained, but design cycle time is extended
Solution Approach 1:
The system performs preliminary automated actions by converting B-Rep lattice models into shell mesh FEA models and executing dynamic crash simulations automatically. This preliminary automation handles routine conversion and simulation tasks, freeing designers to focus on creative aspects while reducing overall design cycle time.
Solution Approach 2:
The system implements feedback loops where simulation results from dynamic crash analysis automatically inform design modifications. The automated workflow allows designers to quickly iterate by adjusting parameters in the B-Rep model, observing simulation results, and refining designs based on quantitative feedback, thus reducing design cycle time while maintaining flexibility.
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: obtaining a skeleton model of a lattice structure, constructing a control point frame surface model using the skeleton model, generating a shell mesh model of the lattice structure using the control point frame surface model, performing numerical simulation of a physical object using the shell mesh model included within a 3D model of the physical object to produce an assessment, modifying the skeleton model or the control point frame surface model based on the assessment to change the lattice structure until it satisfies at least one response requirement, producing from the control point frame surface model a solid body model of the lattice structure hollow beams, and providing at least the solid body model for use in manufacturing a hollow lattice structure.