Computational Design of Lightweight Trusses

Trusses are load-carrying light-weight structures consisting of bars connected at joints ubiquitously applied in a variety of engineering scenarios. Designing optimal trusses that satisfy functional specifications with a minimal amount of material has interested both theoreticians and practitioners for more than a century. In this paper, we introduce two main ideas to improve upon the state of the art. First, we formulate an alternating linear programming problem for geometry optimization. Second, we introduce two sets of complementary topological operations, including a novel subdivision scheme for global topology refinement inspired by Michell's famed theoretical study. Based on these two ideas, we build an efficient computational framework for the design of lightweight trusses. \AD{We illustrate our framework with a variety of functional specifications and extensions. We show that our method achieves trusses with smaller volumes and is over two orders of magnitude faster compared with recent state-of-the-art approaches

Analysis of Mesostructure Unit Cells Comprised of Octet-truss Structures

A unit truss finite element analysis method allowing non-linear deformation is employed to analyze a unit cell comprised of n 3 octet-truss structures for their stiffness and displacement compared to their relative density under loading. Axial, bending, shearing, and torsion effects are included in the analysis for each strut in the octet-truss structure which is then related to the mesostructure level (unit cell). The versatility of additive manufacturing allows for the fabrication of these complex unit cell truss structures which can be used as building blocks for macro-scale geometries. The finite element calculations are compared to experimental results for samples manufactured on a Stereolithography Apparatus (SLA) out of a standard resin.Mechanical Engineerin

Designing Volumetric Truss Structures

We present the first algorithm for designing volumetric Michell Trusses. Our method uses a parametrization approach to generate trusses made of structural elements aligned with the primary direction of an object's stress field. Such trusses exhibit high strength-to-weight ratios. We demonstrate the structural robustness of our designs via a posteriori physical simulation. We believe our algorithm serves as an important complement to existing structural optimization tools and as a novel standalone design tool itself

Extreme mechanical resilience of self-assembled nanolabyrinthine materials

Low-density materials with tailorable properties have attracted attention for decades, yet stiff materials that can resiliently tolerate extreme forces and deformation while being manufactured at large scales have remained a rare find. Designs inspired by nature, such as hierarchical composites and atomic lattice-mimicking architectures, have achieved optimal combinations of mechanical properties but suffer from limited mechanical tunability, limited long-term stability, and low-throughput volumes that stem from limitations in additive manufacturing techniques. Based on natural self-assembly of polymeric emulsions via spinodal decomposition, here we demonstrate a concept for the scalable fabrication of nonperiodic, shell-based ceramic materials with ultralow densities, possessing features on the order of tens of nanometers and sample volumes on the order of cubic centimeters. Guided by simulations of separation processes, we numerically show that the curvature of self-assembled shells can produce close to optimal stiffness scaling with density, and we experimentally demonstrate that a carefully chosen combination of topology, geometry, and base material results in superior mechanical resilience in the architected product. Our approach provides a pathway to harnessing self-assembly methods in the design and scalable fabrication of beyond-periodic and nonbeam-based nano-architected materials with simultaneous directional tunability, high stiffness, and unsurpassed recoverability with marginal deterioration

Design Synthesis of Adaptive Mesoscopic Cellular Structures with Unit Truss Approach and Particle Swarm Optimization Algorithm

Cellular material structures have been engineered at the mesoscopic scale for high performance and multifunctional capabilities. However, the design of adaptive cellular structures - structures with cellular configurations, sizes, and shapes designed for a specific geometric and loading context - has not been sufficiently investigated. In this paper, the authors present a design synthesis method with the use of unit truss approach and particle swarm optimization algorithm to design adaptive cellular structures. A critical review is presented to show the pros and cons of the new design synthesis method and an existing homogenization method. The research extends the application of additive manufacturing in the design of new materials for high performances and benefits its long-term growth.Mechanical Engineerin

Heat conduction in multifunctional nanotrusses studied using Boltzmann transport equation

Materials that possess low density, low thermal conductivity, and high stiffness are desirable for engineering applications, but most materials cannot realize these properties simultaneously due to the coupling between them. Nanotrusses, which consist of hollow nanoscale beams architected into a periodic truss structure, can potentially break these couplings due to their lattice architecture and nanoscale features. In this work, we study heat conduction in the exact nanotruss geometry by solving the frequency-dependent Boltzmann transport equation using a variance-reduced Monte Carlo algorithm. We show that their thermal conductivity can be described with only two parameters, solid fraction and wall thickness. Our simulations predict that nanotrusses can realize unique combinations of mechanical and thermal properties that are challenging to achieve in typical materials

Multiscale Design for Solid Freeform Fabrication

One of the advantages of solid freeform fabrication is the ability to fabricate complex structures on multiple scales, from the macroscale features of an overall part to the mesoscale topology of its internal architecture and even the microstructure or composition of the constituent material. This manufacturing freedom poses the challenge of designing across these scales, especially when a part with designed mesostructure is part of a larger system with changing requirements that propagate across scales. A setbased multiscale design method is presented for coordinating design across scales and reducing iterative redesign of SFF parts and their mesostructures. The method is applied to design a miniature unmanned aerial vehicle system. The system is decomposed into disciplinary subsystems and constituent parts, including wings with honeycomb mesostructures that are topologically tailored for stiffness and strength and fabricated with selective laser sintering. The application illustrates how the design of freeform parts can be coordinated more efficiently with the design of parent systems.Mechanical Engineerin

Space Structures: Issues in Dynamics and Control

A selective technical overview is presented on the vibration and control of large space structures, the analysis, design, and construction of which will require major technical contributions from the civil/structural, mechanical, and extended engineering communities. The immediacy of the U.S. space station makes the particular emphasis placed on large space structures and their control appropriate. The space station is but one part of the space program, and includes the lunar base, which the space station is to service. This paper attempts to summarize some of the key technical issues and hence provide a starting point for further involvement. The first half of this paper provides an introduction and overview of large space structures and their dynamics; the latter half discusses structural control, including control‐system design and nonlinearities. A crucial aspect of the large space structures problem is that dynamics and control must be considered simultaneously; the problems cannot be addressed individually and coupled as an afterthought