Multi-Objective Parametric Shape Optimisation of Body-Centred Cubic Lattice Structures for Additive Manufacturing

There has been significant interest in additively manufactured lattice structures in recent years due to their enhanced mechanical and multi-physics properties, making them suitable candidates for various applications. This study presents a multi-parameter implicit equation model for designing body-centred cubic (BCC) lattice structures. The model is used in conjunction with a multi-objective genetic algorithm (MOGA) approach to maximise the stiffness of the BCC lattice structure while minimising von-Mises stress within the structure under a specific loading condition. The selected design from the MOGA at a specific lattice density is compared with the classical BCC lattice structure and the designs generated by a single-objective genetic algorithm, which focuses on maximising stiffness or minimising von-Mises stress alone. By conducting a finite element analysis on the optimised samples and performing mechanical testing on the corresponding 3D-printed specimens, it was observed that the optimised lattice structures exhibited a substantial improvement in mechanical performance compared to the classical BCC model. The suitability of multi-objective and single-objective optimisation approaches for designing lattice structures was further investigated by comparing the corresponding designs in terms of their stiffness and maximum von-Mises stress values. The results from the numerical analysis and experimental testing demonstrate the significance of the application of an appropriate optimisation strategy for designing lattice structures for additive manufacturing.