The size matching and scaling method: a synthesis method for the design of mesoscale cellular structures

Chang, Patrick; Rosen, David W.

doi:10.1080/0951192x.2011.650880

Cited by 58 publications

(8 citation statements)

References 20 publications

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“…A fundamental benefit of the approach is that it allows the decoupling of variables characterising various structural design aspects -providing greater freedom and control for designer to achieve targeted variation, as seen in Figure 11(A.ii). Similar research has been pursued by Nguyen et al (2012), who developed a framework for individual unit-cell typology selection for LCM, and by Chang (2010), who expanded the research to include member sizing. The hierarchical complexity of LCM also lends organisation for reduced modelling approaches, as typified in methods by Johnston et al's (2006) and Tam et al's (2017b) that consider each unit-cell, rather than the individual struts, as discrete FEA unit for analyses -thereby also reducing the total number of elements required for analysis.…”

Section: Strategies To Simplify Design Problems With Large Variable Smentioning

confidence: 80%

“…Outside of design-oriented investigation, technical research on additive manufacturable LCM in mechanical engineering include experimental analyses of LCM parts additive manufactured using specific AM method (Beyer and Figueroa, 2016), analytical and numerical modelling methods (Deshpande et al, 2001;Johnston et al, 2006), and methods to generate lattice that conform to a given arbitrary design volume, such as the research of Chang (2010), and Nguyen et al (2012), who respectively developed processes for element sizing optimisation and unit topology variation in conformal lattice, and Abd El Malek et al (2005), who incorporated a Heuristic Gradient Projection technique to improve the optimisation of large 3-D space frames. In addition to the focus on stiffness maximisation, mechanical engineering researchers have developed methods for generating LCM to achieve compliant (Li et al, 2009;Zhou, 2010) and dynamic behaviour (Takezawa et al, 2005).…”

Section: Research On Additive Manufactured Lattice Cellular Materialsmentioning

confidence: 99%

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Fabrication-aware structural optimisation of lattice additive-manufactured with robot-arm

Tam¹,

Marshall²,

Gu³

et al. 2018

IJRAPIDM

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Architectural structures achieving high strength and stiffness with intelligent, but intricate geometry may now be materialisable through additive manufacturing (AM). However, conventional layer-based AM also produces parts with inconsistent structural strength -thereby limiting AM's end-use applications. Expanding on robotics-enabled AM techniques addressing this limitation, a novel design-fabrication framework for producing structurally optimised lattices is presented here. Lattices are geometrically morphed to maximise their structural stiffness-to-weight ratio while respecting fabrication constraints imposed by the robotic printing process, and converted into tool-paths for PLA extrusion with a custom-built end effector mounted on an industrial robot arm. The printing process leverages thermal imaging for Lattice additive-manufactured with robot-arm 121 calibration, and develops a novel joint detail to increase the reliability and load-transfer capabilities of the print. Together, these techniques and methods -validated through comparative structural load testing -show promise for architecture-scale AM that combines structurally driven geometry with complexity-agnostic materialisation in new and exciting ways. (2018) 'Fabrication-aware structural optimisation of lattice additivemanufactured with robot-arm', Int. J. Rapid Manufacturing, Vol. 7, Nos. 2/3, pp.120-168. Biographical notes: Kam-Ming Mark Tam is an Integration Engineer at Thornton Tomasetti's CORE Studio and a researcher at the Digital Structures research group (DS) of Massachusetts Institute of Technology's (MIT)Building Technology (BT) programme, where he investigates approaches for design space exploration that combine both structural and fabrication considerations. Specifically, he has developed methods to simplify the design modelling and analyses of complex structural systems, and robotic-enabled additive manufacturing (AM) techniques to create high-performance AM-produced parts. He earned a MEng in Civil Engineering from MIT, and a MArch and a HBAS (with Economics Minor) from the University of Waterloo. He has taught in the Singapore University of Technology and Design and Pratt Institute, and practiced in several architectural firms.

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Section: Strategies To Simplify Design Problems With Large Variable Smentioning

confidence: 80%

Section: Research On Additive Manufactured Lattice Cellular Materialsmentioning

confidence: 99%

Fabrication-aware structural optimisation of lattice additive-manufactured with robot-arm

Tam¹,

Marshall²,

Gu³

et al. 2018

IJRAPIDM

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show abstract

“…Various optimization methods have been employed by researchers to develop lattice structures targeted for specific applications. , These methods have been employed from the standpoint of topological optimization by considering either a grid of framelike structures or a set of predefined unit cell geometries and primitives. Applications such as transmission tower design and cantilever beam optimization have been chosen in literature to showcase this methodology. , The methods stated above impose constraints on the objective functions from the given loading conditions, which are typically in the form of stress or force with emphasis on minimizing mass-maximizing strength.…”

Section: Introductionmentioning

confidence: 99%

Systematic Generation, Analysis, and Characterization of 3D Micro-architected Metamaterials

Trifale

Nauman

Yazawa

2016

ACS Appl. Mater. Interfaces

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Controlling the unit-cell topology of microlattice structures can enable the customization of effective anisotropic material properties. A wide range of properties can be obtained by varying connectivity within the unit cell, which then can be further used to optimize structures specific to applications. A methodology for a systematic generation of microlattice structures is presented that focuses on controlling discrete topology instead of average porosity (as is done in conventional porous media). An algorithm is developed to create valid lattice structures without redundancies from a given set of template nodes. A set of possible permutations of structures from an eight-node cubic octant of a unit cell are generated for evaluation of the degree of anisotropy. Generic models are developed to calculate the effective thermal and mechanical properties as an effect of topology and porosity of the micro-architected structure. The thermal and mechanical anisotropies are investigated for the effective properties of micro-architected materials. A few of the structured materials are fabricated using 3D printing technology and their effective properties characterized. Structures are represented as graphs in the form of adjacency matrices. Effective thermal conductivity is analyzed using a resistance network model, and effective stiffness is evaluated using a self-consistent elastic model, respectively. A total of 160 000 structures are generated and compared to porous-metal foams in which porosity is one of the design variables. The results show that it is possible to obtain a wide range of properties spanning more than an order of magnitude in comparison to porous-metal structures. Structures with a maximum anisotropy ratios of 7.1 and 8.2 are observed for thermal and mechanical properties, respectively. Preliminary experimental results validated the anisotropy ratio for the thermal conductivity and stiffness.

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“…2.1 Lattice Optimization. Although there are currently no preferred optimization approaches for multimaterial lattices, there are a large number of existing approaches for single material lattice structure optimization, such as the size matching and scaling method [22]. The size matching and scaling method has been implemented to design and optimize mesoscale, cellular lightweight structures.…”

Section: Introductionmentioning

confidence: 99%

A Generalized Optimality Criteria Method for Optimization of Additively Manufactured Multimaterial Lattice Structures

Stanković¹,

Mueller

Egan

et al. 2015

Journal of Mechanical Design

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Recent progress in additive manufacturing (AM) allows for printing customized products with multiple materials and complex geometries that could form the basis of multimaterial designs with high performance and novel functions. Effectively designing such complex products for optimal performance within the confines of AM constraints is challenging due to the need to consider fabrication constraints while searching for optimal designs with a large number of variables, which stem from new AM capabilities. In this study, fabrication constraints are addressed through empirically characterizing multiple printed materials' Young's modulus and density using a multimaterial inkjet-based 3D-printer. Data curves are modeled for the empirical data describing two base printing materials and 12 mixtures of them as inputs for a computational optimization process. An optimality criteria (OC) method is developed to search for solutions of multimaterial lattices with fixed topology and truss cross section sizes. Two representative optimization studies are presented and demonstrate higher performance with multimaterial approaches in comparison to using a single material. These include the optimization of a cubic lattice structure that must adhere to a fixed displacement constraint and a compliant beam lattice structure that must meet multiple fixed displacement constraints. Results demonstrate the feasibility of the approach as a general synthesis and optimization method for multimaterial, lightweight lattice structures that are large-scale and manufacturable on a commercial AM printer directly from the design optimization results.

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The size matching and scaling method: a synthesis method for the design of mesoscale cellular structures

Cited by 58 publications

References 20 publications

Fabrication-aware structural optimisation of lattice additive-manufactured with robot-arm

Fabrication-aware structural optimisation of lattice additive-manufactured with robot-arm

Systematic Generation, Analysis, and Characterization of 3D Micro-architected Metamaterials

A Generalized Optimality Criteria Method for Optimization of Additively Manufactured Multimaterial Lattice Structures

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