Porous structures such as trabecular bone are widely seen in nature. These structures are lightweight and exhibit strong mechanical properties. In this paper, we present a method to generate bone-like porous structures as lightweight infill for additive manufacturing. Our method builds upon and extends voxel-wise topology optimization. In particular, for the purpose of generating sparse yet stable structures distributed in the interior of a given shape, we propose upper bounds on the localized material volume in the proximity of each voxel in the design domain. We then aggregate the local per-voxel constraints by their p -norm into an equivalent global constraint, in order to facilitate an efficient optimization process. Implemented on a high-resolution topology optimization framework, our results demonstrate mechanically optimized, detailed porous structures which mimic those found in nature. We further show variants of the optimized structures subject to different design specifications, and we analyze the optimality and robustness of the obtained structures.
To assist users in the design of 3D printed shapes, Stave Stava et al @cite_27 presented a system to detect structural deficiencies by finite element analysis. A set of correction operations including hollowing, thickening, and strut insertion, are proposed to improve the structural soundness. Targeting specifically for reducing the material usage inside a 3D model, @cite_5 introduced skin-frame structures as a composition of the shape interior, and optimized the layout and size of frames. @cite_18 proposed honeycomb-like Voronoi structures to hollow the interior volume, and optimized the distribution and size of Voronoi cells. In early work by @cite_52 , the layout of truss structures is optimized for designing bridges and towers. Manufacturing constraints regarding the avoidance of overhang surfaces and small geometric feature size, have been addressed by @cite_44 via self-supporting rhombic structures for infill optimization. Manufacturable micro-structures have been investigated in graphics @cite_36 @cite_31 @cite_32 and in mechanical topology optimization approaches (e.g., @cite_11 @cite_47 , among others). Our work is inspired by these works , but and builds upon topology optimization which doesn't prescribe the structural composition and thus does not limit the design space.
@cite_18 @cite_47 @cite_36 @cite_52 @cite_32 @cite_44 @cite_27 @cite_5 @cite_31 @cite_11
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The emergence of low-cost 3D printers steers the investigation of new geometric problems that control the quality of the fabricated object. In this paper, we present a method to reduce the material cost and weight of a given object while providing a durable printed model that is resistant to impact and external forces. We introduce a hollowing optimization algorithm based on the concept of honeycomb-cells structure. Honeycombs structures are known to be of minimal material cost while providing strength in tension. We utilize the Voronoi diagram to compute irregular honeycomb-like volume tessellations which define the inner structure. We formulate our problem as a strength--to--weight optimization and cast it as mutually finding an optimal interior tessellation and its maximal hollowing subject to relieve the interior stress. Thus, our system allows to build-to-last 3D printed objects with large control over their strength-to-weight ratio and easily model various interior structures. We demonstrate our method on a collection of 3D objects from different categories. Furthermore, we evaluate our method by printing our hollowed models and measure their stress and weights. Abstract This paper applies topology optimisation to the design of structures with periodic and layered microstructural details without length scale separation, i.e. considering the complete macroscopic structure and its response, while resolving all microstructural details, as compared to the often used homogenisation approach. The approach takes boundary conditions into account and ensures connected and macroscopically optimised microstructures regardless of the difference in micro- and macroscopic length scales. This results in microstructures tailored for specific applications rather than specific properties. Manufacturability is further ensured by the use of robust topology optimisation. Dealing with the complete macroscopic structure and its response is computationally challenging as very fine discretisations are needed in order to resolve all microstructural details. Therefore, this paper shows the benefits of applying a contrast-independent spectral preconditioner based on the multiscale finite element method (MsFEM) to large structures with fully-resolved microstructural details. It is shown that a single preconditioner can be reused for many design iterations and used for several design realisations, in turn leading to massive savings in computational cost. The density-based topology optimisation approach combined with a Heaviside projection filter and a stochastic robust formulation is used on various problems, with both periodic and layered microstructures. The presented approach is shown to allow for the topology optimisation of very large problems in Matlab , specifically a problem with 26 million displacement degrees of freedom in 26 hours using a single computational thread. We propose a method for fabricating deformable objects with spatially varying elasticity using 3D printing. Using a single, relatively stiff printer material, our method designs an assembly of small-scale microstructures that have the effect of a softer material at the object scale, with properties depending on the microstructure used in each part of the object. We build on work in the area of metamaterials, using numerical optimization to design tiled microstructures with desired properties, but with the key difference that our method designs families of related structures that can be interpolated to smoothly vary the material properties over a wide range. To create an object with spatially varying elastic properties, we tile the object's interior with microstructures drawn from these families, generating a different microstructure for each cell using an efficient algorithm to select compatible structures for neighboring cells. We show results computed for both 2D and 3D objects, validating several 2D and 3D printed structures using standard material tests as well as demonstrating various example applications. We present a method for designing truss structures, a common and complex category of buildings, using non-linear optimization. Truss structures are ubiquitous in the industrialized world, appearing as bridges, towers, roof supports and building exoskeletons, yet are complex enough that modeling them by hand is time consuming and tedious. We represent trusses as a set of rigid bars connected by pin joints, which may change location during optimization. By including the location of the joints as well as the strength of individual beams in our design variables, we can simultaneously optimize the geometry and the mass of structures. We present the details of our technique together with examples illustrating its use, including comparisons with real structures. Microstructures at the scale of tens of microns change the physical properties of objects, making them lighter or more flexible. While traditionally difficult to produce, additive manufacturing now lets us physically realize such microstructures at low cost. In this paper we propose to study procedural, aperiodic microstructures inspired by Voronoi open-cell foams. The absence of regularity affords for a simple approach to grade the foam geometry --- and thus its mechanical properties --- within a target object and its surface. Rather than requiring a global optimization process, the microstructures are directly generated to exhibit a specified elastic behavior. The implicit evaluation is akin to procedural textures in computer graphics, and locally adapts to follow the elasticity field. This allows very detailed structures to be generated in large objects without having to explicitly produce a full representation --- mesh or voxels --- of the complete object: the structures are added on the fly, just before each object slice is manufactured. We study the elastic behavior of the microstructures and provide a complete description of the procedure generating them. We explain how to determine the geometric parameters of the microstructures from a target elasticity, and evaluate the result on printed samples. Finally, we apply our approach to the fabrication of objects with spatially varying elasticity, including the implicit modeling of a frame following the object surface and seamlessly connecting to the microstructures. Abstract Recent work has demonstrated that the interior material layout of a 3D model can be designed to make a fabricated replica satisfy application-specific demands on its physical properties, such as resistance to external loads. A widely used practice to fabricate such models is by layer-based additive manufacturing (AM), which however suffers from the problem of adding and removing interior supporting structures. In this paper, we present a novel method for generating application-specific infill structures on rhombic cells so that the resultant structures can automatically satisfy manufacturing requirements on overhang-angle and wall-thickness. Additional supporting structures can be avoided entirely in our framework. To achieve this, we introduce the usage of an adaptive rhombic grid, which is built from an input surface model. Starting from the initial sparse set of rhombic cells, via numerical optimization techniques an objective function can be improved by adaptively subdividing the rhombic grid and thus adding more walls in cells. We demonstrate the effectiveness of our method for generating interior designs in the applications of improving mechanical stiffness and static stability. The use of 3D printing has rapidly expanded in the past couple of years. It is now possible to produce 3D-printed objects with exceptionally high fidelity and precision. However, although the quality of 3D printing has improved, both the time to print and the material costs have remained high. Moreover, there is no guarantee that a printed model is structurally sound. The printed product often does not survive cleaning, transportation, or handling, or it may even collapse under its own weight. We present a system that addresses this issue by providing automatic detection and correction of the problematic cases. The structural problems are detected by combining a lightweight structural analysis solver with 3D medial axis approximations. After areas with high structural stress are found, the model is corrected by combining three approaches: hollowing, thickening, and strut insertion. Both detection and correction steps are repeated until the problems have been eliminated. Our process is designed to create a model that is visually similar to the original model but possessing greater structural integrity. 3D printers have become popular in recent years and enable fabrication of custom objects for home users. However, the cost of the material used in printing remains high. In this paper, we present an automatic solution to design a skin-frame structure for the purpose of reducing the material cost in printing a given 3D object. The frame structure is designed by an optimization scheme which significantly reduces material volume and is guaranteed to be physically stable, geometrically approximate, and printable. Furthermore, the number of struts is minimized by solving an l0 sparsity optimization. We formulate it as a multi-objective programming problem and an iterative extension of the preemptive algorithm is developed to find a compromise solution. We demonstrate the applicability and practicability of our solution by printing various objects using both powder-type and extrusion-type 3D printers. Our method is shown to be more cost-effective than previous works. We introduce elastic textures: a set of parametric, tileable, printable, cubic patterns achieving a broad range of isotropic elastic material properties: the softest pattern is over a thousand times softer than the stiffest, and the Poisson's ratios range from below zero to nearly 0.5. Using a combinatorial search over topologies followed by shape optimization, we explore a wide space of truss-like, symmetric 3D patterns to obtain a small family. This pattern family can be printed without internal support structure on a single-material 3D printer and can be used to fabricate objects with prescribed mechanical behavior. The family can be extended easily to create anisotropic patterns with target orthotropic properties. We demonstrate that our elastic textures are able to achieve a user-supplied varying material property distribution. We also present a material optimization algorithm to choose material properties at each point within an object to best fit a target deformation under a prescribed scenario. We show that, by fabricating these spatially varying materials with elastic textures, the desired behavior is achieved. Abstract We present a method to design manufacturable extremal elastic materials. Extremal materials can possess interesting properties such as a negative Poisson’s ratio. The effective properties of the obtained microstructures are shown to be close to the theoretical limit given by mathematical bounds, and the deviations are due to the imposed manufacturing constraints. The designs are generated using topology optimization. Due to high resolution and the imposed robustness requirement they are manufacturable without any need for post-processing. This has been validated by the manufacturing of an isotropic material with a Poisson’s ratio of ν = - 0.5 and a bulk modulus of 0.2 times the solid base material’s bulk modulus.