DESIGN METHOD AND TAXONOMY OF OPTIMIZED REGULAR CELLULAR STRUCTURES FOR ADDITIVE MANUFACTURING TECHNOLOGIES

Additive manufacturing technologies enable the fabrication of innovative parts not achievable by other technologies, such as cellular structures, characterized by lightness and good mechanical properties. In this paper a novel modeling and optimization method is proposed to design regular cellular structures. The approach is based on generative modeling of a structure by repeating a unit cell inside a solid model, obtaining a beam model, and on an iterative variation of the size of each section in order to get the desired utilization for each beam. Different structures have been investigated, derived by six cell types in two load conditions. Taxonomy of cell types as a function of relative density and compliance were proposed in order to support the design process for additive manufacturing of cellular structures.

[1]  Gianmaria Concheri,et al.  Mechanical characterization of polyamide cellular structures fabricated using selective laser sintering technologies , 2013 .

[2]  M. Ashby,et al.  Effective properties of the octet-truss lattice material , 2001 .

[3]  Dietmar W Hutmacher,et al.  Scaffold-based tissue engineering: rationale for computer-aided design and solid free-form fabrication systems. , 2004, Trends in biotechnology.

[4]  Binil Starly,et al.  Computer-aided characterization for effective mechanical properties of porous tissue scaffolds , 2005, Comput. Aided Des..

[5]  M. H. Luxner,et al.  Finite element modeling concepts and linear analyses of 3D regular open cell structures , 2005 .

[6]  Bernhard Mueller,et al.  Additive Manufacturing Technologies – Rapid Prototyping to Direct Digital Manufacturing , 2012 .

[7]  J. Ramos-Grez,et al.  Elastic tensor stiffness coefficients for SLS Nylon 12 under different degrees of densification as measured by ultrasonic technique , 2008 .

[8]  Ryan B. Wicker,et al.  Open-cellular copper structures fabricated by additive manufacturing using electron beam melting , 2011 .

[9]  Lorna J. Gibson,et al.  Defect sensitivity of a 3D truss material , 2001 .

[10]  M. Ashby,et al.  The topological design of multifunctional cellular metals , 2001 .

[11]  Lorna J. Gibson,et al.  Mechanical behavior of a three-dimensional truss material , 2001 .

[12]  S. Raman,et al.  A design for the additive manufacture of functionally graded porous structures with tailored mechanical properties for biomedical applications , 2011 .

[13]  George I. N. Rozvany,et al.  A critical review of established methods of structural topology optimization , 2009 .

[14]  David W. Rosen,et al.  Computer-Aided Design for Additive Manufacturing of Cellular Structures , 2007 .

[15]  Vikram Deshpande,et al.  The stiffness and strength of the gyroid lattice , 2014 .

[16]  David W. Rosen,et al.  A comparison of synthesis methods for cellular structures with application to additive manufacturing , 2010 .

[17]  Binil Starly,et al.  Bio-CAD modeling and its applications in computer-aided tissue engineering , 2005, Comput. Aided Des..

[18]  Edward J. Garboczi,et al.  Elastic properties of model random three-dimensional open-cell solids , 2002 .

[19]  Alessandro Franco,et al.  Experimental Analysis of Selective Laser Sintering of Polyamide Powders: an Energy Perspective , 2010 .

[20]  David W. Rosen,et al.  A HYBRID GEOMETRIC MODELING METHOD FOR LARGE SCALE CONFORMAL CELLULAR STRUCTURES , 2005 .

[21]  Michael F. Ashby,et al.  Multifunctionality of cellular metal systems , 1998 .