An optimal penalty method for the joint stiffening in beam models of additively manufactured lattice structures

Additive manufacturing is revolutionizing structural design, with lattice structures becoming increasingly prominent due to their superior mechanical properties. However, simulating these structures quickly and accurately using the finite element method (FEM) remains challenging. Recent research has highlighted beam element simulation within FEM as a more efficient alternative to traditional solid FE simulations, achieving similar accuracy with reduced computational resources. However, a significant challenge is managing the lack of rigidity at nodes and the prevalence of low aspect ratio beams. While various methodologies have been proposed to address these issues, there is still a gap in the comprehensive evaluation of their limitations. An optimal node penalization methodology is required to expand the limited range of accurately represented lattice behavior. A preliminary study investigates lattice geometries through comparative analysis of solid and beam FE simulations. Built on this, we developed a methodology suitable to linear, dynamics and nonlinear beam FE simulations, contributing to enhanced computational speed and accuracy. Several lattice structures were printed using material jetting and quasi-static compressive tests were conducted to validate the methodology’s accuracy. The numerical results reveal a good accuracy between the proposed beam FE methodology and the experimental data, offering a better alternative to conventional FEM for energy absorption in terms of computing time. • Optimal penalty parameters are identified through simple static and dynamic problems. • Considering the angles at the junctions is an efficient way to set the penalty region. • Balancing the mass distribution is crucial for dynamic analyses. • The identified penalty method is simple to implement and works for various geometries. • The developed approach leads to beam models that better fit experimental data.