Transitional Lattice Structures for Multi-Cell 3D Printed Parts
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Solution Overview
Problem
Existing lattice structures in additive manufacturing are rigidly defined and unable to conform to shape or load directions, and there is a lack of methods to smoothly interconnect multiple different lattice types in a single object.
Innovation Solution
The development of lattice structures with transition segments that smoothly transition between two types of lattices, allowing for a progressive change in size of lattice unit cells, and the use of additive manufacturing processes such as selective laser sintering, fused deposition modeling, and stereolithography to create these structures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional lattice structures with rigid topology definitions are used, then structural stability is maintained, but the ability to conform to shape or load directions is lost
Solution Approach 1:
The lattice structure transitions from a static, rigid topology to a dynamic system where unit cell sizes can progressively change. The transition segment enables the lattice to adapt its configuration along the length, allowing conformity to different shapes and load directions while maintaining structural integrity through controlled topological variation.
Solution Approach 2:
Different segments of the lattice structure are assigned different unit cell sizes and configurations. The transition segment specifically implements local quality by progressively varying the unit cell dimensions from one end to the other, enabling each region to be optimized for its specific functional requirements while maintaining overall structural coherence.
2Adaptability or versatility
If homogeneous lattice structures with consistent dimensions throughout are used, then manufacturing simplicity is maintained, but the ability to provide varying properties throughout the structure is lost
Solution Approach 1:
The lattice structure is divided into distinct segments: a first lattice portion with initial unit cell characteristics, a transition segment with progressively varying unit cells, and a second lattice portion with final unit cell characteristics. This segmentation allows each region to have optimized properties while maintaining manufacturability through systematic generation of the transition zone.
Solution Approach 2:
The lattice structure implements parameter changes by systematically varying unit cell dimensions along the transition segment. The unit cell size progresses from the dimensions in the first lattice portion to the dimensions in the second lattice portion, enabling gradient properties that adapt to varying functional requirements while maintaining structural continuity.
3Adaptability or versatility
If multiple different lattice types are interconnected, then adaptability to different functional requirements is improved, but the smoothness of interconnection between lattice types is lost
Solution Approach 1:
The transition segment acts as an intermediary between the first lattice portion and the second lattice portion. It provides a gradual transition zone where unit cell sizes progressively change from the characteristics of the first lattice to those of the second lattice, ensuring smooth interconnection and avoiding abrupt transitions that would compromise manufacturing precision or structural integrity.
Data Source
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AI summary
An additively manufactured lattice structure includes (a) a first three-dimensional lattice including a repeating interconnected array of a first lattice unit cell, (b) a second three-dimensional lattice including a repeating interconnected array of a second lattice unit cell, wherein said second lattice unit cell is different from said first lattice unit cell, and (c) a first transition segment interconnecting said first three-dimensional lattice and said second three-dimensional lattice. The first transition segment includes (i) a first three-dimensional transitional lattice including a repeating array of said first lattice unit cell and (ii) interleaved with and interconnected to said first three-dimensional transitional lattice, a second three-dimensional transitional lattice including a repeating array of said second lattice unit cell.