Shape-Conforming Lattice Structures Without Truncated Weak Points
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Solution Overview
Problem
Additive manufacturing of lattice structures often results in structural weaknesses and stress concentrations due to truncation of cellular components to match complex part shapes, complicating the manufacturing process with unwanted artifacts in computer models.
Innovation Solution
A computer modeling and additive manufacturing system that generates a shape-conforming lattice structure by creating a finite element mesh corresponding to the part's overall shape, allowing deformation of lattice structures to match the mesh elements, thereby avoiding structural compromises and enabling parallel processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If lattice structures are truncated to match complex part shapes, then the part conforms to the desired overall shape, but structural weaknesses and stress concentrations are introduced
Solution Approach 1:
The patent applies local quality by making each lattice cellular component unique to its position in the lattice structure. Instead of using uniform truncated cells throughout, each cell is individually generated to match the local geometry of the part surface, ensuring that every cell maintains structural integrity while conforming to the overall complex shape.
Solution Approach 2:
The patent segments the lattice structure into discrete cellular components, where each cell is an independent geometric entity. This segmentation allows each cell to be individually optimized and generated without affecting other cells, enabling the structure to conform to complex shapes while maintaining local structural quality.
2Shape
If orthogonal lattice structures are cropped to fit circular or complex shapes, then the part achieves the desired geometry, but unwanted stress paths and stress concentrations are introduced
Solution Approach 1:
The patent generates lattice cells with local quality by creating unique geometric configurations for each cell based on its specific position and orientation in the lattice structure. This ensures that stress paths are distributed evenly throughout the structure rather than concentrating at truncated edges, as each cell is specifically shaped to maintain structural continuity.
3Shape
If lattice structures are truncated to match part shapes, then the overall shape is achieved, but artifacts are introduced in the computer model complicating additive manufacturing
Solution Approach 1:
The patent uses copying by generating each lattice cellular component as a copy of a base cell geometry that is then locally transformed to match the desired shape. This approach maintains model simplicity by using a single base geometry definition that can be replicated and transformed, rather than creating entirely unique geometries for each cell.
Data Source
AI summary
A system and method of creating a shape-conforming lattice structure for a part formed via additive manufacturing. The method includes receiving a computer model of the part and generating a finite element mesh. A lattice structure including a number of lattice cellular components may also be generated. Some of the mesh elements of the finite element mesh may be deformed so that the finite element mesh conforms to the overall shape of the part. The lattice structure may then be deformed so that the lattice structure has a cellular periodicity corresponding to the finite elements of the finite element mesh. In this way, the part retains the benefits of its overall shape and the benefits of lattice features without introducing structural weak points, directional stresses, and other structural deficiencies.