Transitional Lattice Structures for Seamless 3D-Printed Cell Changes
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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 additively manufactured object, then the versatility and functionality of the lattice structure is improved, but the difficulty of seamless interconnection between different lattice types increases
Solution Approach 1:
The patent introduces a transition segment as an intermediary element between different lattice types. This transition segment contains a gradient of unit cell configurations that gradually transform from one lattice type to another, enabling seamless interconnection without abrupt transitions. The intermediary transition segment resolves the complexity of directly connecting dissimilar lattice structures.
Solution Approach 2:
The patent applies local quality by varying the unit cell characteristics specifically within the transition segment region, while maintaining uniform lattice types in the terminal regions. The transition segment locally modifies unit cell size, shape, or configuration to create a gradual transition, allowing different lattice types to be interconnected without compromising the overall structural integrity or functionality.
2Reliability
If the size of lattice unit cells is progressively changed to create smooth transitions, then the structural integrity and functionality are improved, but the manufacturing complexity increases
Solution Approach 1:
The patent employs parameter changes by systematically varying unit cell dimensions (size, shape, or configuration) along the transition segment. This controlled parameter variation creates smooth transitions between different lattice types while maintaining structural integrity. The progressive change in parameters allows the structure to adapt gradually, avoiding stress concentrations that would compromise reliability.
Solution Approach 2:
The patent divides the lattice structure into distinct segments: terminal regions with uniform lattice types and intermediate transition segments with gradient unit cells. This segmentation allows the complex transition zone to be isolated and managed separately from the simpler terminal regions, facilitating manufacturing by breaking down the overall structure into manageable sections with different fabrication requirements.
3Adaptability or versatility
If transition segments are added to interconnect different lattice types, then the versatility of the lattice structure is improved, but the device complexity increases
Solution Approach 1:
The transition segment serves multiple functions simultaneously: it connects different lattice types, maintains structural integrity, enables gradual property transitions, and facilitates load transfer between dissimilar lattice structures. This multi-functionality justifies the added complexity by providing numerous benefits in a single integrated component.
Solution Approach 2:
The patent addresses the complexity of interconnecting different lattice types by introducing a transitional dimension or zone between them. Rather than attempting direct connection in the same dimensional space, the transition segment creates an intermediate dimensional region where unit cell parameters gradually evolve, allowing smooth transformation between different lattice configurations.
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 transition between different lattice types, enhancing the structural integrity and functionality 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 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.