Local Thickness Optimization of Functionally Graded Lattice Structures in Compression

This paper presents a new method for optimizing the thickness distribution of a functionally graded lattice structure. It links the thickness of discrete lattice regions via mathematical functions, reducing the required number of optimization variables while being applicable to highly nonlinear models and arbitrary optimization goals. This study demonstrates the method’s functionality by altering the local thickness of a lattice structure in compression, optimizing the structure’s specific energy absorption at constant weight. The simulation results suggest significant improvement potential for the investigated Simple Cubic lattice, but less so for the Isotruss variant. The energy absorption levels of the physical test results closely agree with the simulations; however, great care must be taken to accurately capture material and geometry deviations stemming from the manufacturing process. The proposed method can be applied to other lattice structures or goals and could be useful in a wide range of applications where the optimization of lightweight and high-performance structures is required.