Lattice structure design with topology optimization and additive manufacturing

Abstract

Structure can get various mechanical characteristics by applying periodic structures as typified by lattice structures. Lattice structures are generally used inside the structural member in order to reduce the weight. One advantage of lattice structures is that we do not need to change the whole structural shape when we replace the solid part of a component with the lattice structures. Another advantage is the lightness of the weight, and hence it is important to design a high performance lattice shape with low weight. However, a framework for development of micro lattice structures considering both stiffness and weight has not been established. Thus, we propose a method for designing and producing micro lattice structures. We use a topology optimization method for a designing methodology. Topology optimization is an effective method in designing high performance lattice structure since topology optimization allows us to change the topology and to design a complicated shape. We use a metal additive manufacturing (AM) machine for producing the optimal lattice structures. AM allows us to produce a complicated structure which removal and forming manufacturing cannot produce. We use a bulk modulus as the objective function since it is one of the important mechanical characteristics in design. In this research, we use a homogenization method to compute the bulk modulus. Objective function was modified so that isotropy of the optimal shape is retained when the solution is updated. In addition, structures produced by AM need holes so that internal metal powder can be removed. Hence, we defined the design domain so that the optimal structure becomes open cell structure. Then, high bulk modulus shapes were derived using topology optimization. The lattice structures were produced by metal AM machine after being modified for production.