Sandwich Panel Infill Structure for Consistent Face-Sheet Interfaces
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Solution Overview
Problem
Conventional additive manufacturing of sandwich panels results in irregular and inconsistent topology at the interfaces between the inner core and face sheets, leading to manufacturing challenges and stress concentrations.
Innovation Solution
A method and system for generating a panel infill geometry using a driver mesh and reference unit cell meshes, adjusted through basis functions to conform to hexahedral elements, resulting in a consistent topology at the interfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional additive manufacturing uses prior art infill geometry with orthogonally-repeating structural pattern, then the manufacturing process is simple, but the topology at interfaces between inner core and face sheets becomes irregular and inconsistent
Solution Approach 1:
The infill geometry is divided into multiple unit cells, each containing a standardized structural pattern. These unit cells are systematically arranged and mapped to hexahedral elements, ensuring consistent topology at interfaces while maintaining manufacturing simplicity through modular repetition.
Solution Approach 2:
The invention transforms the infill geometry generation by changing parameters such as unit cell size, shape, and arrangement to conform to hexahedral element boundaries. This parameter optimization ensures that the infill structure maintains consistent topology at face sheet interfaces while adapting to the specific geometric requirements of the sandwich panel.
2Reliability
If prior art infill geometry is used, then the structural pattern is uniform and easy to manufacture, but stress concentrations occur at interface locations
Solution Approach 1:
The infill geometry is designed with varying local properties: unit cells near face sheet interfaces are configured to ensure consistent topology and reduce stress concentrations, while interior unit cells maintain uniform structural patterns. This local differentiation improves reliability at critical interfaces without significantly complicating the overall manufacturing process.
3Manufacturing precision
If conventional infill geometry is fabricated, then the manufacturing process is straightforward, but the footprint pattern at interface locations is inconsistent
Solution Approach 1:
The infill geometry is pre-configured with unit cells that are specifically designed to conform to hexahedral element boundaries before fabrication. This preliminary design ensures that when the geometry is fabricated using additive manufacturing, the footprint pattern at interface locations is consistent and predictable, without requiring post-processing adjustments that would reduce productivity.
Data Source
AI summary
A sandwich panel has a first face sheet and a second face sheet, at least one of which is non-planar. In addition, the sandwich panel has a panel infill structure comprising an array of unit cell structures arranged in at least one layer connecting the first face sheet to the second face sheet. Each unit cell structure has a main axis that is locally normal to an imaginary mid-surface located midway between the first face sheet and the second face sheet. The panel infill structure has a consistent topology at each interface location where a unit cell structure is connected to the first face sheet or the second face sheet.