Transitional Lattice Structures for Seamless Multi-Cell 3D Printing
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Solution Overview
Problem
Existing additive manufacturing techniques struggle to seamlessly interconnect multiple different lattice types in a single object, limiting the versatility and functionality of lattice structures in applications such as bumpers, pads, and shock absorbers.
Innovation Solution
The development of lattice structures with transition segments that smoothly connect different lattice types, allowing for a gradual transition between them through a process of additive manufacturing, where the size of lattice unit cells progressively changes to ensure a cohesive and functional integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple different lattice types are interconnected in a single object, then the versatility and functionality of lattice structures is improved, but the difficulty of seamless integration and structural coherence deteriorates
Solution Approach 1:
The patent applies local quality by creating transition segments with spatially varying lattice unit cell sizes. The lattice structure transitions from one type to another through a gradient where unit cell dimensions change continuously in specific regions, allowing different lattice types to be integrated seamlessly while maintaining structural coherence at each location.
Solution Approach 2:
The patent employs parameter changes by systematically varying the size of lattice unit cells within transition segments. The unit cell dimensions are progressively adjusted from the dimensions in the first lattice type to the dimensions in the second lattice type, enabling a smooth transition that maintains structural integrity while accommodating multiple lattice types in a single object.
2Stability of the object's composition
If lattice unit cell sizes are progressively changed to transition between lattice types, then the structural integrity and coherence of the transition segment is improved, but the manufacturing complexity and process difficulty deteriorates
Solution Approach 1:
The patent applies dynamics by implementing a gradient transition where lattice unit cell sizes change continuously through the transition segment rather than remaining static. This dynamic variation in unit cell dimensions allows the structure to adapt smoothly between different lattice types, maintaining structural integrity while the additive manufacturing process captures this gradual transformation.
Solution Approach 2:
The patent employs preliminary action by designing and planning the gradient transition segment in advance before manufacturing. The varying unit cell sizes are pre-calculated and programmed into the additive manufacturing process, allowing the complex gradient structure to be built systematically layer by layer without requiring complex real-time adjustments during manufacturing.
3Manufacturing precision
If transition segments with varying lattice unit cell sizes are created, then the seamless integration of different lattice types is improved, but the design and generation complexity deteriorates
Solution Approach 1:
The patent applies dimensionality change by extending the lattice design from discrete uniform units to continuous gradients in unit cell size. This adds a dimensional aspect of gradual size variation within the transition segment, enabling seamless integration of different lattice types through controlled changes in unit cell dimensions across the transition region.
Solution Approach 2:
The patent employs segmentation by dividing the overall lattice structure into distinct regions: a first lattice type region, a transition segment region with varying unit cell sizes, and a second lattice type region. This segmentation allows each region to be designed and optimized independently while ensuring seamless integration through the transition segment that bridges the two lattice types.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the creation of complex lattice structures that are rigid, flexible, or elastic, suitable for various applications, including wearable protective devices and automotive components, by allowing for the seamless integration of different lattice types, enhancing the structural integrity and adaptability of additively manufactured products.
Implementation Method 1
A group of additive manufacturing techniques sometimes referred to as 'stereolithography' create a three-dimensional object by the sequential polymerization of a light polymerizable resin
Data Source
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 the second lattice unit cell is different from the first lattice unit cell, and (c) a first transition segment interconnecting the first three-dimensional lattice and the second three-dimensional lattice. The first transition segment includes (i) a first three-dimensional transitional lattice including a repeating array of the first lattice unit cell and (ii) interleaved with and interconnected to the first three-dimensional transitional lattice, a second three-dimensional transitional lattice including a repeating array of the second lattice unit cell.