Development of Customized Algorithms for the Semi-Automatic Generation of Gradient, Conformal Strut-Based Lattice Structures Using Rhino 8 and Grasshopper: Application and Flexural Testing

In recent years, significant advancements have been made in the field of design for additive manufacturing (DfAM). These advancements have focused on key aspects such as topology optimization (TO), generative design (GD), lattice structures, and AI-based algorithms. This paper presents a methodology for developing custom Grasshopper® algorithms to create strut-based, gradient, and conformal lattice structures. Two test geometries were devised and imported into Grasshopper®, and different lattice structures with varying settings, such as conformity, lattice topology, and strut diameter gradient and cell size gradient, were generated and manufactured. A series of experiments was conducted to assess the impact of input parameters on the formation of lattice structures, their performance in three-point bending tests, and their effect on functionality, applicability, and usability. The experimental investigation yielded clear findings regarding the usability and functionality of the proposed algorithm. However, the findings indicate that although the overall process is usable, improvements are required to streamline the algorithm in order to avoid geometry generation errors and to make it more user-friendly. This approach presents a low-cost, customizable alternative to commercial lattice generation tools, with direct integration in Rhino 8 and Grasshopper®.