A parametric mesostructural approach for robust design of additive manufacturing parts

Abstract

Additive Manufacturing (AM) allows for production of potentially complex design solutions and motivates the use of Structural Optimization tools in product development to chase the structural limit of a design problem and its solution concept. Scratching on the limits of the material strength, design solutions can lack robustness concerning simplifications in model assumptions and uncertainties. However, the design freedom with AM can also actively be used to enhance robustness and reliability of solutions. To this end, an approach is presented that introduces Parametric Mesostructures into selective areas of the Additive Design. Structural members and coherent mechanical characteristics of these mesostructures can significantly reduce local stress peaks and can account for uncertainties, e.g. direction of load application. Their design is motivated by Structural Optimization and analysis results. Implementation of the approach is demonstrated and discussed on the example of a structural aircraft component