Finite-Element-Mesh Based Method for Modeling and Optimization of Lattice Structures for Additive Manufacturing

Area of Science:

• Materials Science
• Mechanical Engineering
• Computational Modeling

Background:

• Additive manufacturing (AM) enables complex geometries, but designing large-scale, optimized lattice structures remains challenging.
• Existing methods often lack the flexibility to create graded or non-uniform structures with tailored mechanical properties.

Purpose of the Study:

• To present a parameterization modeling method using finite element meshes for complex lattice structures in AM.
• To develop a size optimization approach for lattice structures to enhance mechanical performance.

Main Methods:

• A finite element meshing technique is used to define lattice structures based on geometry, element types, and node connectivity.
• Parametric descriptions of lattice unit cells allow for assembly and modification (node movement, cross-sectional area changes).
• The moving iso-surface threshold (MIST) method is employed for size optimization to improve mechanical properties.

Main Results:

• The proposed method facilitates the creation of graded and non-uniform lattice structures.
• Numerical examples and experimental testing validate the modeling and optimization approach.
• Experimental results show an 11% increase in stiffness for optimized non-uniform lattice structures compared to uniform ones.

Conclusions:

• The finite element mesh-based parameterization method offers a flexible approach for designing complex lattice structures in AM.
• The MIST-based optimization effectively enhances the mechanical performance of lattice structures.
• This integrated approach holds significant potential for developing advanced AM components with improved functionality.