Design Optimization of Lattice Structures Under Impact Loading for Additive Manufacturing

Abstract Additive manufacturing (AM) has enabled the production of intricate lattice structures with excellent performance and minimal mass. Design approaches that consider static loading, including lattice-based topology optimization (TO), have been well-researched recently. However, to date, there appears to be no widely accepted method of optimizing lattice structures for high-strain rate loading, especially when the design for additive manufacturing (DFAM) principles are considered. This study proposes a computational framework for the design of lattice structures under specified impact loading. To manage dimensionality while achieving sufficient generality, a heuristic design space is developed that relies on traditional TO to govern the design's macrostructure and standard dimensioning to govern its mesostructure. DFAM principles are then incorporated into a Bayesian optimization scheme wrapped around traditional TO to achieve manufacturable designs that absorb high-impact loading. Because this approach does not require analytical gradient information, the framework can be used to optimize directly on complex objectives, such as injury metrics calculated from the acceleration curve. A series of case studies is formulated around a mass-performance tradeoff and involves individual unit cell design as well as full-part design. The proposed design parameterization is found to enable sufficient flexibility to achieve consistently good performance regardless of AM build orientation.