Parts internal structure definition using non-uniform patterned lattice optimization for mass reduction in additive manufacturing

Today, being able to generate and produce shapes that fit mechanical and functional requirements and having as low as possible mass is crucial for aerospace and automotive applications. Besides, the rise of new additive manufacturing technologies has widened the possibilities for designing and producing complex shapes and internal structures. However, current models, methods and tools still represent a limitation to that new horizon of printable shapes. This paper addresses the way internal lattice structures can be generated and optimized to reduce the mass of a product. A new framework is introduced that allows the modeling and optimization of non-uniform patterned lattice structures. Using non-uniform structures, additional degrees of freedom are introduced and allow the definition of a wide variety of shapes which can better fit the requirements. First, a non-uniform patterned lattice structure is generated using the results of an initial finite element analysis. This initial structure is then optimized while iteratively removing the beams considered as useless with respect to a user-specified mechanical criteria. At each iteration, the lattice structure is sent to a finite element solver that returns the von Mises stress map used to drive the simplification process. Here, the simulations are performed on the wireframe lattice structures to speed up the optimization loops. Once this process is completed, the final structure is no longer fully patterned, but it is re-organized to reduce the mass while satisfying the mechanical criteria. This approach is illustrated with examples coming from our prototype software.