FE vibration analyses of novel conforming meta-structures and standard lattices for simple bricks and a topology-optimized aerodynamic bracket.

Additive manufacturing (AM) enables production of components that are not possible to make using traditional methods. In particular, lattice-type structures are of recent interest due to their potential for high strength-to-weight ratios and other desirable properties. However, standard periodic lattice structures have problems conforming to complex curved and multi-connected shapes (e.g. holes or sharp-to-smooth mating edges). In addition, standard lattices have well known shear and fatigue weaknesses due to their periodic basis/structure. To address these problems, we developed a new type of shape-conforming meta-structure (HGon) that extends lattices, enabling automated conforming to complex shapes and parametric meta-topology control. HGons also have unique vibration dampening and optimization capabilities. This study presents initial FE analyses of (Part 1) dynamic vibration responses of new HGon meta-structures compared with periodic lattices of equivalent density for a series of basic rectangular structures and (Part 2) a complex multi-connected aerodynamic bracket with field-based stress meta-topology optimization. Results show significantly enhanced vibration dampening behavior and superior strength-to-weight ratios for HGon meta-structures as compared to standard lattices.