United Cellular Lattice Structure Without Shared Face Removal
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Solution Overview
Problem
The process of creating united cellular lattice structures in additive manufacturing is time-intensive due to the need to identify and remove shared face surfaces between lattice cells, which can lead to computational errors and manufacturing imperfections.
Innovation Solution
A method is developed to generate a united cellular lattice structure by dividing a part volume into subvolumes with specific side combinations, creating modified lattice cells that only have face surfaces on non-adjoining sides, and inserting these cells into corresponding subvolumes to form the lattice structure without searching for and removing shared face surfaces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the traditional method of merging lattice cells with searching and removing shared face surfaces is used, then the united cellular lattice structure can be created, but the process is time-intensive and significantly slows computation
Solution Approach 1:
The patent divides the part volume into multiple subvolumes, with each subvolume containing a modified lattice cell. This segmentation approach allows each cell to be processed independently with pre-determined face surface configurations based on its position, eliminating the need for global searching and removal operations while maintaining structural accuracy.
Solution Approach 2:
The patent applies preliminary action by pre-determining which face surfaces to remove based on the lattice cell's position within the part volume before merging operations. By identifying and removing the appropriate face surfaces in advance during cell generation, the system avoids time-intensive searching and removal operations during the merging phase, significantly improving computation speed while maintaining reliability.
2Manufacturing precision
If shared face surfaces are removed through intensive searching and removal processes, then the lattice structure accuracy can be maintained, but computational errors and manufacturing imperfections may still occur
Solution Approach 1:
The system performs preliminary determination of which face surfaces to remove based on the lattice cell's position within the part volume before the merging operation. By pre-configuring modified lattice cells with the correct face surfaces removed according to their positional context, the system eliminates uncertainty and potential errors associated with post-merger detection and removal, ensuring manufacturing precision and reliability.
Solution Approach 2:
The patent replaces the mechanical searching and removal process with a computational approach that determines face surface removal based on lattice cell position. Instead of physically searching for and removing shared face surfaces after merging, the system uses positional information to pre-determine which surfaces to remove, substituting a reliable computational method for a error-prone mechanical process.
3Manufacturing precision
If all adjoining face surfaces are properly removed, then the lattice structure is accurate, but it is difficult to determine if all surfaces have been removed properly
Solution Approach 1:
The system performs preliminary determination of face surface removal based on the lattice cell's position within the part volume before merging. By pre-configuring modified lattice cells with the correct face surfaces removed according to their positional context, the system eliminates the need for complex verification processes, as the correctness of face surface removal is determined in advance through positional logic.
Data Source
AI summary
A system and method for generating a computer-based united cellular lattice structure includes dividing a part volume into a number of adjacent subvolumes each having a side combination corresponding to a number and orientation of adjoining sides and non-adjoining sides. A modified lattice cell may be generated from a base lattice cell for each side combination of the subvolumes such that each modified lattice cell has face surfaces on faces thereof corresponding to non-adjoining sides and does not have face surfaces on faces thereof corresponding to adjoining sides. Copies of the modified lattice cells may then be generated and inserted into corresponding subvolumes such that the faces of the modified lattice cell copies having face surfaces are positioned along non-adjoining sides of the subvolumes and faces of the modified lattice cell copies not having face surfaces are positioned along adjoining sides of the subvolumes.