3D-Printed Tessellated Lattice Structures With Stronger Interfaces
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Solution Overview
Problem
Existing multi-morphological and multi-material lattice structures exhibit poor structural integrity and functional performance due to abrupt transitions and poor bonding at interfaces, leading to stress concentration and challenging fabrication with current additive manufacturing technologies that require excessive support structures.
Innovation Solution
Design of tessellation-based lattice structures using Simple Cubic (SC), Body Centered Cubic (BCC), and Face Centered Cubic (FCC) tessellations with Urchin-inspired basic unit lattice cells that can be stacked without supports, providing edge-to-edge connectivity and allowing for the creation of Functionally Tessellated (FT) lattice structures with different mechanical and functional properties, enabling multi-material-like behavior.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multi-morphological lattice structures are used to achieve different structural and functional properties, then multi-material like properties are obtained, but structural integrity deteriorates at interfaces due to abrupt transitions
Solution Approach 1:
The patent applies local quality by transitioning from abrupt morphological changes to gradual transitions. The lattice structure uses progressively changing unit cell morphologies (from cubic to dodecahedral to icosahedral) along the interface, creating a gradient that smoothly bridges different structural properties while maintaining structural integrity. This gradual transition prevents stress concentration by distributing mechanical loads across the transition zone rather than concentrating them at sharp interfaces.
Solution Approach 2:
The patent employs parameter changes by systematically varying the morphology parameters of unit cells along the interface. The coordination number and geometric parameters of lattice units are progressively modified to create functionally graded structures. This continuous parameter variation enables smooth transitions between different structural regions, achieving multi-material like properties while maintaining excellent interface strength through controlled morphological evolution.
2Ease of manufacture
If support structures are added to enable fabrication of complex lattice structures, then fabrication feasibility is improved, but manufacturing complexity and material consumption increase
Solution Approach 1:
The patent applies preliminary action by designing the lattice structure with built-in support features during the design phase. The unit cells incorporate integrated support elements and anchoring mechanisms that provide necessary support during fabrication without requiring separate support structures. This preliminary incorporation of support functionality simplifies the manufacturing process and reduces post-processing requirements.
Solution Approach 2:
The lattice structure employs self-service by using its own structural elements to provide mutual support during fabrication. The interconnected unit cells with their geometric configurations inherently provide support to each other, eliminating the need for external support structures. The structure supports itself through its design, reducing manufacturing complexity and material consumption while maintaining fabrication feasibility.
3Ease of manufacture
If support structures are used during additive manufacturing, then fabrication of overhanging locations is enabled, but manufacturing time and energy consumption increase
Solution Approach 1:
The patent applies the taking out principle by completely removing the need for separate support structures from the manufacturing process. The lattice design extracts the support function from external elements and integrates it into the structural units themselves. This elimination of dedicated support structures significantly reduces manufacturing time and energy consumption while maintaining the capability to fabricate complex overhanging geometries through the self-supporting unit cell designs.
4Adaptability or versatility
If multi-material lattice structures are used to achieve different properties, then functional versatility is improved, but bonding properties at joints deteriorate
Solution Approach 1:
The patent applies homogeneity by using a single material throughout the entire lattice structure rather than combining multiple materials. The unit cells are fabricated from uniform material composition, ensuring consistent bonding properties and mechanical characteristics throughout the structure. This homogeneous material approach eliminates interfacial bonding issues between dissimilar materials while maintaining functional versatility through morphological variation of the unit cells.
Data Source
AI summary
The metallic crystal structures inspired edge-to-edge tessellations and a tessellation based lattice structures are disclosed. In accordance with an exemplary embodiment of the invention, basic unit lattice cells are stacked and connected to constitute a three-dimensional tessellations, wherein each of the basic unit lattice cells comprises a multiple flat connecting portions formed on a surface of the basic unit lattice cell and intersecting with a multiple of axes intersecting in a center of the basic unit lattice cell, and the flat connecting portions of one of the basic unit lattice cell is connected to the flat connecting portions of the adjacent basic unit lattice cell to constitute a connection structure of edge-to-edge tessellation. The formed tessellations are periodically tessellated in a design domain to form different tessellated lattice structures. The Functionally Tessellated (FT) lattice structures composed of different tessellations by interlocking into each other are also disclosed.