Multi-lattice Design for Laser Powder Bed Fusion via Multi-scale Post-processing of Topology Optimization Results
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A common approach to achieving multi-scale design is the Functionally Graded Lattice Structure (FGLS). A highly efficient method for obtaining the FGLS design is also the multi-scale post-processing of an unmodified Solid Isotropic Material with Penalization (SIMP) optimization, which interprets the intermediate densities as lattice structure. However, there is no universally superior lattice cell; different loads or purposes require different lattice topologies. The solution is to combine multiple lattice cells in one design, creating so-called multi-cell design. In the past years, the number of papers addressing multi-cell topology optimization (TO) has rapidly increased. The most popular approaches use homogenization pre-processing and multi-variable algorithms. This study presents a workflow that does not address TO itself, but focuses on post-processing the optimized results from SIMP and reliably creating ready-to-manufacture geometry. The proposed workflow is based on a library of predefined cubic lattice cells that are connectable in any combination and are distributed in the design according to local loading conditions and the suitability of each cell. It leverages the natural anisotropy of truss-based lattice cells without horizontal struts, making it optimal for supportless manufacturing using Laser Powder Bed Fusion technology. The main advantages of the proposed workflow are the low computational cost of TO and fast and efficient solution. Numerical examples demonstrate that the workflow is highly efficient in terms of stiffness-to-weight ratio, even when compared to a mono-scale design, a post-processed design with FGLS, or a lattice solution obtained using commercial software.
