
Hybrid Lattice Structure Optimization for Additive Manufacturing
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Topology optimization is a well-known method to determine the optimal structural design adapted to a given set of material amounts, loads, and boundary conditions. Combining this method with functionally graded lattices allows for an even greater freedom of design. While in recent years the possibilities enabled by additive manufacturing have raised increased attention related to structural optimization, the investigation of metal-printed lattice structures and their unique mechanical properties is still in its early stages. Here, we investigate five distinct topology optimization strategies—solid-only, lattice-only, solid-then-lattice, lattice-then-solid, and solid and lattices concurrently—on the structural performance of hybrid lattice-solid structures fabricated from AlSi10Mg via powder bed fusion (PBF). Utilizing a novel 4D hierarchical interpolation model, we developed an optimized structural design method that uses three families of micro-structures to achieve superior stiffness-to-weight ratios in response to a given external load. Additionally, fully solid, fully lattice, and concurrently optimized structures were experimentally printed and tested by means of a three-point bending test for validating compliance and comparing energy absorption. We demonstrate the impact of different optimization strategies on structural performance, combining detailed numerical analysis of deformation under three-point bending with comprehensive experimental investigations focusing on failure analysis. The results indicate significant variations in compliance and energy absorption based on the selected design strategy, with the concurrent optimization strategy demonstrating the most favorable balance between them. Experimental outcomes strongly correlate with numerical predictions, underscoring the effectiveness of concurrent optimization of hybrid lattice-solid structures for lightweight, high-performance engineering applications.