A Comparison of Synthesis Methods for Cellular Structures with Application to Additive Manufacturing

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Chu, Jane
Engelbrecht, Sarah
Graf, Greg
Rosen, David W.

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Cellular material structures, such as honeycombs and lattice structures, have been engineered at the mesoscale for high performance and multifunctional capabilities. We desire efficient algorithms for searching the large, complex design spaces associated with cellular structures. In this paper, we present a comparison of two synthesis methods, Particle Swarm Optimization (PSO) and least-squares minimization (LSM), for the design of components comprised of cellular structures. Computational characteristics of the algorithms are reported for design problems with hundreds of variables. Constraints from SLS and direct-metal manufacturing processes are incorporated to ensure that resulting designs are realizable. Two 2- dimensional examples are used to study the characteristics of the proposed synthesis methods.


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