A parametric model of joint-enhanced truss lattices with optimization for superior mechanical properties

Abstract

Advancements in additive manufacturing have enabled the incorporation of microstructures into macroscopic designs, allowing for tailored mechanical properties. However, conventional truss lattices, despite their simplicity and ease of fabrication, are prone to stress concentrations at joints, leading to fractures and structural failure under high stress. This study introduces Parametric Joint-Enhanced Truss Lattices (PETL), a model designed to redistribute mass around joints, reducing stress concentrations and enhancing both the strength and stiffness of truss structures. By incorporating smoothness parameters, PETL achieves improved stress distribution and mechanical performance while maintaining the original truss skeleton. Seamlessly integrating with level-set optimization, the PETL model supports the design of structures tailored to specific mechanical property requirements. Simulations and physical experiments demonstrate that PETL consistently outperforms traditional truss lattice designs, delivering superior stress distribution, increased stiffness, and enhanced structural strength under equivalent conditions. By expanding the design space of truss lattices, PETL holds significant potential for advancing material and structural performance in additive manufacturing.