Research on Lightweight Design and Performance Optimization of Lattice Structures Based on Additive Manufacturing

Hongfang Shan*; Xiaolin Wang; Yunfei Jiang; Nuo Xu

doi:10.71451/ISTAER2556

Authors

Hongfang Shan* Swinburne College of Shandong University of Science and Technology, Jinan, China Author https://orcid.org/0009-0002-7009-8608
Xiaolin Wang Swinburne College of Shandong University of Science and Technology, Jinan, China Author https://orcid.org/0009-0006-2697-9976
Yunfei Jiang Swinburne College of Shandong University of Science and Technology, Jinan, China Author https://orcid.org/0009-0005-8798-283X
Nuo Xu Swinburne College of Shandong University of Science and Technology, Jinan, China Author https://orcid.org/0009-0002-2897-2728

DOI:

https://doi.org/10.71451/ISTAER2556

Keywords:

Lattice structure; Additive manufacturing; Lightweight design; Performance optimization; Process adaptability

Abstract

Addressing the urgent need for lightweight and functionally integrated structures in aerospace, transportation, and other fields, this paper focuses on the systematic design and performance optimization of additive manufacturing-based lattice structures. To overcome the core challenge of the disconnect between theoretical models and manufacturing practice in lattice structure design, this study constructs a comprehensive research system encompassing theoretical modeling, process adaptation, performance optimization, and experimental verification. First, the equivalent mechanical properties of lattice structures are explored in depth, and process adaptability design criteria for additive manufacturing are established to address manufacturability issues. Then, a multi-objective optimization method is used to synergistically improve the static and dynamic mechanical properties and energy absorption characteristics of the lattice structures. Finally, experimental prototypes are prepared by carefully selecting additive manufacturing process parameters, and systematic mechanical performance tests are conducted to verify the accuracy of the numerical model and the effectiveness of the optimized design. The research results not only demonstrate the enormous potential of additively manufactured lattice structures in terms of lightweighting and multifunctional load-bearing capacity but also provide a closed-loop methodology covering design, manufacturing, and performance evaluation for their engineering applications, possessing significant theoretical and engineering reference value.

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