Data-Driven Bi-Directional Lattice Property Customization and Optimization

Customizing and optimizing lattice materials poses a challenge to designers. This study proposed a data-driven generative method to customize and optimize lattice material. The method utilizes subdivision modeling to parametrically describe lattice morphologies and skeletons. Next, the homogenization method is employed to analyze elastic moduli for collecting a dataset. Then, a two-tiered machine learning (ML) framework is proposed to predict the elastic modulus for a forward design. The first-tier model employs polynomial regression to estimate relative density, which serves as an additional input feature for the second-tier model. The prediction accuracy of the second-tier model is improved through the additional inputs. The forward and reverse design strategies offer a flexible and accurate means of tailoring lattice properties to meet specific performance requirements. Two case studies demonstrate the practical value of the framework: customizing a lattice material to achieve a desired elastic modulus and optimizing the mechanical performance of lattice materials under relative density constraints. The results show that the prediction accuracy of the elastic modulus using the two-tiered ML model achieved an error of less than 10% compared to finite element analysis, demonstrating the reliability of the proposed approach. Furthermore, the optimization design achieved up to a 25% improvement in mechanical performance compared to conventional lattice configurations under the same relative density constraints. These findings underscore the advantages of combining generative design, machine learning, and genetic algorithms to navigate complex design spaces and achieve enhanced material performance.