Improving mechanical properties of lattice structures using nonuniform hollow struts

In contrast to constant-strut lattices, the introduction of innovative strut designs has the potential to enhance the mechanical properties of lattice structures. This study presents a Bézier curve-based nonuniform section design for body-centered cubic lattices with hollow struts (BCCH). Periodic boundary conditions are applied to the unit cells, and a finite element (FE) numerical homogenization method is employed to assess their elastic properties. A comprehensive dataset is generated through the FE model, which is subsequently divided into training, validation, and testing sets. The coordinates of the Bézier curve control points serve as inputs to deep learning networks, which are trained on the training dataset. Relative density and elastic properties are treated as two distinct networks, with the validation set utilized to prevent overfitting. The objective function consists of two weighted components: one aims to maximize the relative Young's modulus, while the other ensures that the relative density achieves a specified value. An evolutionary algorithm is employed to optimize the objective function, with variations in the control point coordinates constrained to specific ranges. By leveraging the fast inference ability of the deep learning model, the stiffness and orientation-dependent mechanical properties can be efficiently tailored. Our results demonstrate that the optimized structures demonstrate superior stiffness (+92.8 %) and distributed stress field compared to the benchmark lattice. The design method also enables tailoring of specific mechanical properties, including isotropic elasticity. 3D-printed lattice designs were fabricated and compression tests confirmed agreement with simulation results in terms of stiffness. Additionally, the optimized designs exhibit superior strength (+99.6 %) and toughness compared to the benchmark lattices.