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Topology Optimization Design and Mechanical Properties of 3D-Printed Solid-Lattice Hybrid Structures with
Hongyong Jiang1,2, Xincheng Liu1, Zhihui Liu3
1School of Mechanical Engineering and Electronic Information, China University of Geosciences, Wuhan, Hubei, China.
3D Printing and Additive Manufacturing
|June 20, 2025
Summary
Topology-optimized solid-lattice hybrid structures offer enhanced performance for lightweight design. Variable-density lattices significantly improve peak force and structural efficiency in complex applications.
Area of Science:
- Materials Science
- Mechanical Engineering
- Additive Manufacturing
Background:
- Achieving structural lightweight and high performance simultaneously is a key challenge in engineering design.
- Traditional solid structures often face limitations in weight reduction without compromising mechanical integrity.
- Lattice structures offer potential for lightweighting but can have limitations in stiffness and load-bearing capacity.
Purpose of the Study:
- To propose and investigate topology-optimized solid-lattice hybrid structures for improved lightweight design.
- To explore the effects of variable-density and iso-density lattice configurations within hybrid structures.
- To validate the effectiveness of a novel solid-lattice hybridization-based topology optimization method.
Main Methods:
- Utilizing the Solid Isotropic Material with Penalties (SIMP) topology optimization method.
- Designing and fabricating pure solid, pure lattice, and solid-lattice hybrid structures using selective laser sintering (SLS) additive manufacturing.
- Conducting three-point bending tests and finite element simulations to analyze mechanical behavior and failure modes.
Main Results:
- Solid-lattice hybrid structures, particularly with variable-density lattices, exhibited the highest peak force.
- Pure lattice structures demonstrated high energy absorption capabilities, failing at the largest displacement.
- Distributed lattices effectively alleviated stress concentrations in topology-optimized solid regions, enhancing structural efficiency.
Conclusions:
- Solid-lattice hybridization is a promising approach for achieving superior lightweight and high-performance structures.
- Variable-density lattice integration significantly boosts structural efficiency and peak load capacity.
- The developed topology optimization method provides a valuable framework for designing advanced lightweight components, such as automotive crash beams.
