SYSTEMS AND METHODS FOR GENERATING A SHAPE-BASED GRADED LATTICE STRUCTURE AND THEIR APPLICATION TO ADDITIVE MANUFACTURING

Abstract: systems and methods for generating a shape-based graded lattice structure that can be used in additive manufacturing. a slicer computer system generates the lattice structure by simulating the packing of a planar region with variable-sized packing shapes, where packing shape sizes correspond to intensity values of a non-uniform physical field expected to be experienced by the article. an intermediate lattice structure is then generated using a first set of polygonal cells, followed by a second set of polygonal cells that refine the final lattice structure. tailored sectioning and field-based smoothing can modify polygon packing algorithms to adapt lattice generation. the resultant multi-stage graded lattice structures, which may include multiple lattice patches and transition zones, from shape-based packing, tailored sectioning, field-based smoothing, and slicer-based additive manufacturing processing improve connectivity and manufacturability over traditional lattice structures.

Inventor(s): Seokpum Kim, John C. Bowers, Kenneth Stephenson, Vlastimil Kunc, Ahmed Arabi Hassen, Lonnie J. Love, Gregory D. Dreifus

CPC Classification: B29C64/386 (Data acquisition or data processing for additive manufacturing)

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