A Quasi-Optimal Shape Design Method for Lattice Structure Construction

Abstract Lattice structures, characterized by their distinctive mechanical properties, are widely used in industries such as aerospace, automotive, and biomedical. Their advantages primarily lie in the interconnected struts. The robust construction of these struts is crucial for downstream design and manufacturing applications, as it provides a detailed shape description necessary for precise simulation and fabrication. However, constructing lattice structures presents significant challenges, particularly at nodes where multiple struts intersect. The complexity of these intersections can lead to robustness issues. To address this challenge, this article presents an optimization-based approach that simplifies the construction of lattice structures by cutting struts and connecting them to optimized node shapes. By utilizing the recent grey wolf optimization method—a type of meta-heuristic method—for node shape design, the approach ensures robust model construction and optimal shape design. Its effectiveness has been validated through a series of case studies with increasing topological and geometric complexity, achieving a maximum reduction in shape deviation of 66%. Our implementation and associated data are available on our project webpage.2