Slicer systems for generating a molecular dynamic graded lattice structure and their application to additive manufacturing
Inventors
KIM, Seokpum • Hassen, Ahmed Arabi • Love, Lonnie J. • Kunc, Vlastimil
Assignees
Publication Number
US-12233603-B2
Publication Date
2025-02-25
Expiration Date
2041-05-28
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Abstract
Slicer system for generating molecular dynamic graded lattice structures that can be used as infill for additively manufactured articles. Molecular dynamically generated lattice infill is based on force balancing a node distribution instead of a circle packing. Field data can be utilized to adjust the spacing of the node distribution according to a force balance equilibrium model that accounts for the field expected to be experienced by the article being additively manufactured. The resultant non-uniform honeycomb structures from force-balancing robustly and efficiently address the connection issues with traditional non-uniform lattice structures.
Core Innovation
The invention provides systems and methods for generating non-uniform, graded lattice infill structures for additively manufactured articles. Instead of conventional approaches that rely on circle packing or uniform lattice unit sizes, the disclosed systems base lattice infill generation on force-balancing a node distribution, using field data to create a force balance equilibrium model. This model adjusts node spacing to reflect the expected field (such as stress or temperature) experienced by the article. The non-uniform honeycomb structures resulting from this method robustly address connectivity issues found in traditional non-uniform lattices.
The problem addressed by the invention is the inability of existing additive manufacturing lattice infill generation methodologies to produce non-uniform infill structures that robustly connect patches of different unit cell sizes, particularly when responding to graded physical fields like stress or temperature. Previous approaches either produce uniform lattices or only allow simple thickening of edges, which can lead to poor connectivity, inefficiency, manufacturing complications, and lack the ability to adapt lattice cell size based on functional conditions.
The core innovation integrates physical field data—such as stress or temperature—into the lattice infill generation process using a molecular dynamics-inspired approach. Force balancing is employed to alter node spacing according to variations in the field, leading to a graded lattice structure where regions of high field intensity have smaller lattice cells and regions of low field intensity have larger cells. This method incorporates triangulation and dual graph generation to produce robust, non-uniform polygonal (typically honeycomb) structures with smooth or sectioned transitions between varying lattice cell sizes, enabling tailored mechanical or thermal properties in the final manufactured article.
Claims Coverage
The patent includes one independent claim that details a slicer computer system for additive manufacturing, which incorporates several main inventive features.
Slicer computer system capable of generating non-uniform infill lattice structures based on field data
A slicer computer system comprising: - Memory for storing surface data of an article, field data representing intensity values of a non-uniform physical field corresponding to the article, a slicer software program, and additive manufacturing instructions. - A processor that executes the slicer program to convert both surface and field data into additive manufacturing instructions for fabricating a non-uniform infill lattice structure.
Node positioning and force-balanced spacing adjusted by physical field intensity
Simulation of positioning a plurality of nodes over a planar region corresponding to an infill layer portion, and simulation of adjusting the spacing of those nodes based on the intensity values of the non-uniform physical field at their locations. This yields a node distribution that reflects the functional field expected to be experienced by the article.
Generation of intermediate and final lattice structures using triangulation and dual graphing
Simulation of generating an intermediate lattice structure with polygonal cells where vertices correspond to neighboring nodes, and generating the final infill lattice structure where vertices correspond to centers of adjacent intermediate lattice cells, resulting in a set of lattice polygonal cells for the infill.
Conversion of the simulated infill lattice to additive manufacturing instructions
Conversion of the infill lattice polygonal cells as defined by the simulation into additive manufacturing instructions for printing a physical infill lattice structure, and storing those instructions in memory.
In summary, the independent claim covers a slicer computer system with integrated field-data-responsive node positioning, lattice structure generation through triangulation and dual graphing, and conversion to actionable additive manufacturing instructions, enabling robust, non-uniform lattice infill adapted to the anticipated physical field.
Stated Advantages
Provides a simple and effective way to generate non-uniform infill based on a functional condition, such as internal stress or temperature fields.
Ensures robust connectivity and continuous interfaces between lattice patches of differing unit cell sizes, addressing connectivity issues found in previous non-uniform lattice structures.
Enables efficient and tailored adaptation of lattice cell sizes according to graded physical fields, optimizing material distribution and performance.
Can improve static load-bearing and mechanical performance metrics compared to conventional uniform infill structures.
Documented Applications
Generation of infill lattice structures for additively manufactured articles such as a wing, a propeller blade, a turbine blade, a beam, or a toe of an excavator cup.
Use in both small-scale and large-scale additive manufacturing systems to fabricate articles with non-uniform, field-responsive lattice infill.
Fabrication of parts experiencing graded stress or temperature fields, optimizing the infill structure to match anticipated physical conditions.
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