Design of a double-optimized lattice structure using the solid isotropic material with penalization method and material extrusion additive manufacturing

Han Wool Kim, Young Seong Kim, Joong Yeon Lim

Research output: Contribution to journalArticlepeer-review

4 Scopus citations

Abstract

The development of additive manufacturing technology has facilitated the production of cellular structures such as lattices. Topology optimization is a tool for computing the optimal geometry of an object within certain conditions, and it can be used to increase the stiffness and decrease the weight. In this study, a “double-optimized lattice structure” was designed by applying the solid isotropic material with penalization method for topology optimization twice, first to optimize the unit cell of the lattice and then to grade and insert the cells into a global model. This design was applied to a Messerschmitt–Bölkow–Blohm beam and produced via material extrusion additive manufacturing. Subsequently, it was evaluated by a three-point bending test, and the results indicated that the double-optimized lattice beam had a 1.6–1.9 fold greater effective stiffness and a 2 fold higher ultimate load than the values obtained for the beam designed with conventional methods. Thus, the double-optimized lattice structure developed herein can be an effective material with regard to its low weight and high stiffness. Contrarily, the penalty factor p of the solid isotropic material with penalization did not affect the properties. This finding suggests that p can control homogeneity while maintaining the strength of the structure.

Original languageEnglish
Pages (from-to)3447-3458
Number of pages12
JournalProceedings of the Institution of Mechanical Engineers, Part C: Journal of Mechanical Engineering Science
Volume234
Issue number17
DOIs
StatePublished - 1 Sep 2020

Keywords

  • finite element
  • functionally graded structure
  • Lattice
  • material extrusion additive manufacturing
  • solid isotropic material with penalization
  • topology optimization

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