A non-uniform lattice design method for lightweight structures in 3D printing

Lightweight design is an essential topic in aerospace, automotive and other fields. In automobile manufacturing, the engine connecting rod is one of the main components; its lightweight design has a high reference value. And 3D printing provides a feasible solution for designing and manufacturing lightweight structures. Unlike the traditional geometrically homogeneous point design, this study offers a non-homogeneous point design method based on the spatial stress state of additively manufactured components. After numerical simulation of quasi-static stresses on a model of an engine connecting rod, finite element grid cells with different stress values are replaced by lattice cells with different specific stiffnesses at similar local stress levels. The overall specific stiffness of the structure is further improved by continuing the optimized design with the corresponding gradient-type reinforcement of the non-uniform lattice structure. The basic idea of this design is to perform non-uniform adaptive filling of solid parts under localized loading by employing different types of unit cells. Stereolithography 3D printing technology prepares the engine lattice structural parts for quasi-static compression comparison experiments and fracture analysis after failure. The conclusions show that the engine connecting rod members with non-homogeneous lattice have more excellent overall mechanical properties than homogeneous lattice members. This work demonstrates the feasibility of such design methods for 3D printing lightweight structures and optimization.