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Optimal and adaptive lattice design considering process-induced material anisotropy and geometric inaccuracy for additive manufacturing

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Abstract

High-resolution additive manufacturing (AM) facilitates engineering applications of cellular lattices with complex geometries. The unique layer-by-layer process of AM causes the mechanical performance of as-fabricated lattice structures to deviate from the ideal value. In this study, the AM process-induced material anisotropy and geometric inaccuracy are integrated into the mechanical evaluation and topology optimization of lattice structures. Specifically, effective mechanical properties of typical strut-based and shell-based lattices are evaluated by the homogenization method combined with the process-induced features. The equivalent stiffness parameters of ideal and as-fabricated lattices are integrated into the topology optimization algorithm to adaptively obtain corresponding macrostructures. Based on the knowledgebase of unit cells and optimized results, the threshold of the variation for microstructure is extracted to guide design and process parameter selection. The proposed design guidelines and evaluation-adjustment framework can be widely applied to various lattices fabricated by AM technologies.

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Acknowledgements

This work is supported by the NSAF (U1930207), Key Project of NSFC (51790171), NSFC for Excellent Young Scholars (11722219), NSFC for Young Scholars (51905439), and 111 Project (B21013).

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Authors and Affiliations

  1. State IJR Center of Aerospace Design and Additive Manufacturing, School of Mechanical Engineering, Northwestern Polytechnical University, Xi’an, 710072, Shaanxi, China

    Shaoying Li, Shangqin Yuan, Jihong Zhu, Weihong Zhang, Chuang Wang & Jiang Li

  2. MIIT Lab of Metal Additive Manufacturing and Innovative Design, NPU-QMUL Joint Research Institute, Northwestern Polytechnical University, Xi’anShaanxi, 710072, China

    Jihong Zhu

  3. Unmanned System Research Institute, Northwestern Polytechnical University, Xi’an, 710072, Shaanxi, China

    Shangqin Yuan

  4. Mechanical and Aerospace Engineering Department, Monash University, Melbourne, VIC, 3800, Australia

    Yunlong Tang

  5. Materials Science and Engineering Department, Monash University, Melbourne, VIC, 3800, Australia

    Yunlong Tang

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  1. Shaoying Li
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Correspondence to Shangqin Yuan.

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Li, S., Yuan, S., Zhu, J. et al. Optimal and adaptive lattice design considering process-induced material anisotropy and geometric inaccuracy for additive manufacturing. Struct Multidisc Optim 65, 35 (2022). https://doi.org/10.1007/s00158-021-03153-1

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