Tubular Lattice Structures for Durable 3D Fabricated Objects
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Solution Overview
Problem
Existing 3D fabricated objects with surface-based lattice structures often fail to achieve intended properties like stiffness and compression due to computational inefficiencies and stress concentration at nodes, while beam-based structures lack durability.
Innovation Solution
A processor determines lattice structures with hollow tubes and capped ends using specific equations and constants, minimizing computational resources by defining minimal thickness and adding cap ends to open edges, allowing 3D fabrication systems to interpret these as solid elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If surface-based lattice structures are used, then manufacturing precision and structural integrity are improved, but computational complexity increases and stress concentration occurs at nodes
Solution Approach 1:
The lattice structure is segmented into tubular elements with capped ends rather than continuous surfaces. This segmentation reduces computational complexity by simplifying the mathematical representation while maintaining structural integrity through the capped tube design that eliminates node stress concentrations.
Solution Approach 2:
The patent applies curvature by capping the tubular lattice elements with rounded ends rather than sharp corners. This curvature distributes stress more evenly throughout the structure, eliminating stress concentration at nodes while maintaining manufacturing precision for additive fabrication processes.
2Productivity
If beam-based lattice structures are used, then computational efficiency is improved, but durability and stress distribution deteriorate
Solution Approach 1:
The patent uses thin-walled tubular structures that combine the computational efficiency of beam-like elements with the durability of shell structures. The tubular geometry with capped ends provides better stress distribution than traditional beam elements, improving durability while maintaining relative computational efficiency through simplified geometric representation.
3Quantity of substance
If lattice structures are designed with minimal thickness, then material usage and computational resources are reduced, but structural strength deteriorates
Solution Approach 1:
The patent creates composite structural elements by combining tubular lattice members with capped ends. This composite design allows for minimal thickness in the tubular sections to reduce material usage, while the capped ends provide structural reinforcement to maintain strength, achieving an optimal balance between material efficiency and structural integrity.
Data Source
AI summary
According to examples, a processor may access a digital model of a portion of an object and identify a lattice structure to be formed in an interior of the digital model, in which the identified lattice structure is to provide the portion with a predefined property and is defined by an equation that includes constants. The processor may also determine values of the constants that result in surfaces of the lattice structure forming tubes, determine locations at which the identified equation with the determined values of the constants intersects with the defined boundaries, and modify the digital model to include the lattice structure with the surfaces forming tubes and cap ends added at determined locations to close open edges of the tubes at the determined locations, in which the portion is to be fabricated by a 3D fabrication system according to the modified digital model to have the predefined property.