DESIGN AND ANALYSIS OF ENERGY ABSORPTION

INFLUENCED LATTICE STRUCTURES

A PROJECT REPORT

Submitted by

JAIDEEP KUMAR K (920420UME016)

PREM KUMAR V V (920420UME031)
SARAVANA KUMAR C (920420UME041)

in partial fulfillment for the award of the degree of

BACHELOR OF ENGINEERING
IN
MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

KAMARAJ COLLEGE OF ENGINEERING AND TECHNOLOGY
(An Autonomous Institution Affiliated to Anna University, Chennai)
K.VELLAKULAM, VIRUDHUNAGAR - 625 701

APRIL 2024
KAMARAJ COLLEGE OF ENGINEERING AND TECHNOLOGY
(An Autonomous Institution Affiliated to Anna University, Chennai)
K.VELLAKULAM, VIRUDHUNAGAR - 625 701

BONAFIDE CERTIFICATE

Certified that the project report “DESIGN AND ANALYSIS OF ENERGY

ABSORPTION INFLUENCED LATTICE STRUCTURES” is the bonafide
work of “JAIDEEP KUMAR K (920420UME016), PREM KUMAR V V
(920420UME031) & SARAVANA KUMAR C (920420UME041)” who
carried out the project work under my supervision.

SIGNATURE SIGNATURE
Dr.THANGAKASIRAJAN, M.E, Ph.D Mr. N.R.MADHAN, M.E, (Ph.D)

HEAD OF THE DEPARTMENT, SUPERVISOR,

Associate Professor,
Dept. of Mechanical Engineering,
Kamaraj College of Engg & Tech,
K.Vellakulam,
Virudhunagar - 625 701.
Assistant Professor,
Dept. of Mechanical Engineering,
Kamaraj College of Engg &Tech,
K.Vellakulam,
Virudhunagar - 625 701.

INTERNAL EXAMINER EXTERNAL EXAMINER

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 ACKNOWLEDGEMENT

The success of any project depends on the people associated with it. We are
indebted to everyone who has made valuable contribution towards the success of
this project. We would like to take this opportunity to acknowledge the enthusiasm
of all the personalities.

We wish to express our sincere thanks to our principal Dr. S.SENTHIL,

M.E., Ph.D. and who provided us an opportunity to complete this project a
successful one.

We extend our heartiest thanks to Dr. S.THANGA KASI RAJAN M.E.,

Ph.D. Associate Professor & Head, Department of Mechanical Engineering for his
valuable suggestion throughout the work.

We also extend our sincere thanks to our guide Mr. N.R.MADHAN, M.E.,
(Ph.D), Assistant Professor, Department of Mechanical Engineering for moral
guidance, support and encouragement in completing the project.

We wish to record our sincere thanks to our project coordinator

Mr. R.SAKTHIVELMURUGAN, M.E, (Ph.D)., Assistant Professor Department
of Mechanical Engineering for their continuous suggestion and guidance at every
stage of the work.

We also take this opportunity to thank our family members, teaching faculties,
nonteaching staffs and neighbours who encouraged us by giving their ideas and full
support during the course of our project.

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 ABSTRACT

This study focuses on the design and analysis of lattice structures, which are
increasingly used in engineering applications due to their lightweight nature and
exceptional mechanical properties. The objective is to optimize the energy absorption
performance of lattice structures while considering factors such as material selection,
geometric configuration, and manufacturing feasibility. A literature review is conducted to
explore existing studies on lattice structures and energy absorption mechanisms. A
systematic approach is proposed, using Finite Element Analysis (FEA) to simulate the
behaviour of different lattice configurations under different loading conditions.
Optimization techniques, including topology optimization, are used to refine lattice designs
iteratively to maximize energy absorption efficiency while minimizing weight and material
usage. Sensitivity analysis is conducted to investigate the influence of design parameters
and material properties on energy absorption behaviour. Experimental validation is
conducted to verify the predicted energy absorption performance of the optimized lattice
structures. The findings contribute to the development of lightweight and efficient energy
absorption solutions for engineering applications like automotive crashworthiness, impact
protection systems, and structural reinforcements.

Keywords: Lattice structures, Energy absorption, Finite element analysis, Optimization,

Additive manufacturing.

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 TABLES OF CONTENT

CHAPTER TITLE PAGE NO

ACKNOWLEDGEMENT iii

ABSTRACT ⅶ

LIST OF FIGURES ⅹi

LIST OF SYMBOLS AND ABBREVIATIONS ⅺi

1 INRODUCTION 1

1.1 ENERGY ABSORBTION 1

1.2 LATTICES DESIGN 3

1.3 SHAPE OPTIMIZATION 5

1.4 LACTTICES TESTING 7

2 LITERATURE SURVEY 9

2.1 ENERGY ABSORBTION 9

2.2 LATTICES DESIGN 12

2.3 SHAPE OPTIMIZATION 15

2.4 LACTTICES TESTING 18

2.5 OBSERVATION 21

3 MATERIALS 23

3.1 THERMOPLASTIC POLYURETHANE 23

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 3.2 NYLONE 24

3.3 POLYPROPYLENE 25

3.4 OBSERVATION 26

3.5 WHY TPU? 26

4 PROCESS PLANNING 27

4.1 CONCEPTUALIZATION AND SURVEY 28

4.2 DESIGN DEVELOPMENT 28

4.3 PROTOTYPE 29

4.4 TESTING AND EVALUATION 30

4.5 DESIGN REFINEMENT 31

4.6 PRODUCT 31

5 METHODOLOGY 33

5.1 MATERIAL SELECTION 34

5.2 LATTICE STRUCTURE DESIGN 36

5.3 FINITE ELEMENT ANALYSIS (FEA) 37

5.4 OPTIMIZATION 39

5.5 ADDITIVE MANUFACTURING 41

5.6 EXPERIMENTAL VALIDATION 43

5.7 DATA ANALYSIS 45

6 LIMITATIONS 42

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7 THREE DIMENSIONAL DIAGRAM 49

7.1 DIAGRAM 50

7.2 IMAGE 50

7.3 CUT SECTION OF ASSEMBLY 51

7.4 ASSEMBLY 51

8 STRESS ANALYSIS 52

8.1 ISOMETRIC VIEW REPORT 52

8.2 FRONT VIEW 53

8.3 SIDE VIEW 53

8.4 RESULTS 55

8.4.1 Final Output 56

8.5MAXIMUM RANGE OF STATIC ANALYSIS58

9 CONCLUSION 60

10 PROJECT OUTCOME 61

REFERENCES 65

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 LIST OF FIGURES

FIGURE NO TITLE PAGE NO

3.1 THERMOPLASTIC POLYURETHANE 23

3.2 NYLON 24

3.3 POLYPROPYLENE 25

3.5 WHY TPU? 26

4.1 PROCESS PLANNING 27

5.1 METHODOLOGY 33

7.1 DIAGRAM 50

7.2 IMAGE 50

7.3 CUT SECTION OF ASSEMBLE 51

7.4 ASSEMBLY 51

8.1 ISOMETTRIC VIEW REPORT 53

8.2 FRONT VIEW 54

8.3 SIDE VIEW 54

8.4 RESULT 56

8.4.1 FINAL OUTPUT OF LATTICE DESIGN 57

8.5 MAXIMUM RANGE OF STATIC ANALYSIS 59

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 LIST OF SYMBOLS AND ABBREVIATIONS

℃ - Degree Celsius

% - Percentage

CAD - Computer-Aided Design

FEA - Finite Element Analysis

TPU - Thermoplastic Polyurethane

MPa - Megapascal (unit of pressure)

CFD - Computational Fluid Dynamics

PP - Polypropylene

AR - Augmented Reality

FE - Finite Element

AM - Additive Manufacturing

AMLS - Additive Manufacturing and Laser Sintering

TPMS - Tire Pressure Monitoring System

LCTPMS - Low-Cost Tire Pressure Monitoring System

HIVE - Highly Immersive Virtual Environment

HCOOH - Formic Acid

H2O - Water

CO2 - Carbon Dioxide

KMW - Kilo Mega Watt

M - Meter

CFRP - Carbon Fiber Reinforced Plastic

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Ti42Nb - Titanium-Niobium alloy

IGA - Ionization Gas Analyzer

PTC - Positive Temperature Coefficient

BCC - Body-Centered Cubic (crystal structure)

FCC - Face-Centered Cubic (crystal structure)

SEM - Scanning Electron Microscopy

TEM - Transmission Electron Microscopy

XRD - X-Ray Diffraction

TPR - Temperature Programmed Reduction

XPS - X-ray Photoelectron Spectroscopy

MAM - Multi-Agent Modelling

Ai12Si - Aluminium-Silicon alloy

Ti6A14V - Titanium Aluminium Vanadium

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 CHAPTER 1

INTRODUCTION

Lattice structures, prized for their mechanical prowess, lightweight

composition, and multifaceted applications in engineering, boast a unique blend
of strength, stiffness, and energy absorption capabilities. This paper outlines a
systematic methodology for crafting and assessing lattice structures engineered
to optimize energy absorption. Leveraging finite element analysis (FEA),
various lattice configurations are scrutinized under diverse loading scenarios,
with a keen eye on stress-strain responses and energy dissipation traits.
Employing optimization techniques like topology and parameter optimization
fine-tunes designs, ensuring optimal energy absorption efficiency within
specified design constraints. Sensitivity analysis further refines designs,
shedding light on how design parameters and material properties influence
energy absorption behavior. Experimental validation seals the process,
confirming predicted energy absorption performance.

1.1 ENERGY ABSORBTION

Energy absorption is a foundational concept in engineering, serving as a

crucial mechanism for protecting structures, components, and individuals from
the potentially devastating effects of external forces and impacts. Across a
broad spectrum of industries including automotive, aerospace, sports
equipment, and protective gear, the ability to dissipate kinetic energy efficiently
is paramount for ensuring safety, durability, and performance. At its core,
energy absorption involves the conversion of kinetic energy from an impacting
force into other forms, such as deformation, heat, or work, thereby reducing the
severity of impacts and minimizing damage.

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 Understanding and optimizing energy absorption properties are
fundamental for enhancing the resilience and survivability of engineering
systems in real-world scenarios. The significance of energy absorption is
particularly evident in automotive engineering, where the implementation of
energy-absorbing materials and structures is essential for mitigating the impact
of collisions and protecting vehicle occupants.

By strategically incorporating features such as crumple zones, airbag

systems, and impact-absorbing materials, automotive engineers can minimize
the risk of injury and maximize occupant safety during crashes. Similarly, in
aerospace applications, energy absorption technologies play a critical role in
ensuring the integrity and survivability of aircraft structures during emergency
landings or crash scenarios.

Aircraft components are often equipped with energy-absorbing features

designed to dissipate kinetic energy and minimize structural damage, thereby
safeguarding passengers and critical systems. Beyond automotive and aerospace
industries, energy absorption finds extensive applications in sports equipment
and protective gear, where it contributes to reducing the risk of injury during
high-impact events. Helmets, padding, and other safety equipment utilize
energy-absorbing materials to absorb and dissipate kinetic energy, thereby
minimizing the force transmitted to the wearer's body and reducing the risk of
head trauma or soft tissue injuries. Moreover, in industrial settings, energy
absorption technologies play a vital role in enhancing workplace safety by
protecting workers from the impact of heavy machinery or falling objects.

By understanding the underlying mechanisms and optimizing energy

absorption properties, engineers can develop innovative solutions that enhance
safety, minimize risks, and drive advancements across various industries.
Emerging trends in energy absorption research include the development of

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advanced materials with tailored properties for specific applications, as well as
the integration of smart technologies and predictive analytics to optimize energy
absorption performance in real-time. In conclusion, energy absorption is a
cornerstone of engineering design, essential for ensuring the safety, resilience,
and performance of structures, components, and individuals in the face of
external forces and impacts. By advancing our understanding of energy
absorption mechanisms and exploring innovative solutions, engineers can
continue to push the boundaries of safety and performance across diverse
industries, driving progress and innovation in the field of engineering.

1.2 LATTICES DESIGN

Lattice structures stand at the forefront of engineering innovation,

captivating attention for their remarkable mechanical properties, lightweight
composition, and versatile applications across various disciplines. These
intricate frameworks offer a unique amalgamation of strength, stiffness, and
energy absorption capabilities, rendering them indispensable in industries
spanning automotive, aerospace, sports equipment, and protective gear.

Central to their allure is the ability to tailor both geometry and material
properties to precise specifications, allowing engineers to optimize energy
absorption performance to meet specific design requirements and performance
objectives. The design process of lattice structures is a multifaceted endeavor,
blending artistry with scientific rigor to achieve optimal outcomes. At its
inception, the design phase commences with meticulous consideration of
functional requirements, environmental factors, and performance criteria.
Engineers delve into a vast expanse of design possibilities, exploring a myriad
of lattice geometries, cell shapes, and material compositions to ascertain the
most suitable configuration for the intended application.

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 Leveraging advanced computational tools and simulation techniques,
such as finite element analysis (FEA), engineers scrutinize the mechanical
behavior of lattice structures under diverse loading conditions, unraveling
insights into stress distribution, deformation characteristics, and energy
absorption potential. This iterative process of analysis and refinement enables
engineers to iteratively optimize lattice designs, striking an exquisite balance
between structural integrity, energy absorption efficiency, and
manufacturability.

Optimization techniques, including topology optimization and parameter

optimization, serve as indispensable tools in this quest for design perfection,
guiding engineers towards innovative solutions that push the boundaries of
performance and efficiency. Sensitivity analysis further enhances design
robustness, offering valuable insights into the influence of design parameters
and material properties on energy absorption behavior, thereby informing
strategic design decisions. Throughout the design journey, interdisciplinary
collaboration and cross-functional expertise play a pivotal role, fostering
synergies between design, materials science, and manufacturing disciplines to
achieve holistic design excellence.

Experimental validation serves as the ultimate litmus test, providing

empirical evidence to validate the predicted energy absorption performance of
optimized lattice structures. Through a meticulous process of prototyping,
testing, and refinement, engineers gain confidence in the efficacy and reliability
of their designs, paving the way for real-world deployment and application. In
essence, the design of lattice structures represents a harmonious fusion of art
and science, where creativity converges with analytical rigor to unlock new
frontiers of engineering ingenuity and innovation. As industries continue to
embrace the transformative potential of lattice structures, the quest for ever

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more sophisticated and efficient designs remains a perpetual journey of
exploration and discovery.

1.3 SHAPE OPTIMIZATION

Shape optimization, a cornerstone of engineering design, embodies the

relentless pursuit of form that maximizes performance, efficiency, and
functionality across a myriad of applications. At its essence, shape optimization
transcends mere aesthetics, delving deep into the intricacies of geometry to
unlock untapped potential and elevate engineering solutions to unprecedented
heights. This iterative process begins with a meticulous examination of design
requirements, performance objectives, and constraints, laying the groundwork
for a journey of discovery and innovation. Armed with computational tools and
advanced simulation techniques, engineers embark on a quest to sculpt shapes
that defy convention and surpass expectations.

Finite element analysis (FEA), computational fluid dynamics (CFD), and

other simulation methods serve as invaluable allies, providing insights into the
behavior and performance of proposed designs under diverse operating
conditions. As engineers navigate the complex landscape of design space,
optimization algorithms emerge as indispensable tools, guiding the evolution of
shapes towards optimal configurations that balance competing objectives and
constraints.

From topology optimization, which explores the distribution of material

within a given volume to maximize structural performance, to parameter
optimization, which fine-tunes geometric parameters to achieve desired
outcomes, a plethora of techniques converge to drive innovation and efficiency.

Sensitivity analysis further enriches the design process, unraveling the

intricate interplay between design variables and performance metrics, thereby
empowering engineers to make informed decisions and refine their designs
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iteratively. Throughout this iterative journey, interdisciplinary collaboration and
cross-functional expertise play a pivotal role, fostering synergies between
design, analysis, and manufacturing disciplines to realize the full potential of
shape optimization.

The implications of shape optimization reverberate across diverse

industries, from automotive and aerospace to architecture and biomedical
engineering, where optimized shapes unlock new realms of performance,
efficiency, and sustainability.

In automotive design, for instance, shape optimization enables the

creation of aerodynamic profiles that minimize drag and maximize fuel
efficiency, while in aerospace, it facilitates the development of lightweight
structures that enhance flight performance and reduce fuel consumption.

In architecture, shape optimization fosters the creation of sustainable

buildings that harness natural resources efficiently and minimize environmental
impact, while in biomedical engineering, it drives the design of patient-specific
implants and prosthetics that optimize biomechanical performance and enhance
patient outcomes.

As industries embrace the transformative potential of shape optimization,

the boundaries of engineering design are continually pushed, paving the way for
a future defined by innovation, efficiency, and sustainability.

In conclusion, shape optimization stands as a testament to the power of

human ingenuity, unlocking new frontiers of performance, efficiency, and
functionality across diverse domains. Through a relentless pursuit of form that
transcends conventional boundaries, engineers harness the potential of shape
optimization to redefine what is possible and shape a future that is both bold and
visionary.

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1.4 LATTICES TESTING

Lattice testing is a pivotal phase in the development and validation of

lattice structures, essential for ensuring their performance, reliability, and safety
across diverse engineering applications. As lattice structures gain prominence
for their exceptional mechanical properties, lightweight nature, and versatile
applications, rigorous testing protocols become imperative to ascertain their
suitability and efficacy in real-world scenarios.

The testing process encompasses a comprehensive array of

methodologies, ranging from material characterization and mechanical testing to
structural validation and performance evaluation. At the outset, material
properties of lattice constituents are meticulously characterized through a series
of tests, including tensile, compression, and flexural tests, to ascertain
mechanical behavior and ensure compliance with desired specifications.
Concurrently, structural integrity testing is conducted to assess the robustness
and load-bearing capacity of lattice structures under various loading conditions,
such as static, dynamic, and fatigue loading.

Utilizing advanced testing apparatuses and instrumentation, engineers

scrutinize the structural response of lattice structures, measuring parameters
such as stress distribution, strain accumulation, and deformation characteristics
to elucidate their performance under real-world operating conditions.
Additionally, impact testing plays a pivotal role in evaluating the impact
resistance and energy absorption capabilities of lattice structures, simulating
high-energy events such as collisions or impacts to assess their ability to
dissipate kinetic energy and mitigate damage.

Through quasi-static and dynamic impact tests, engineers glean insights

into the behavior of lattice structures during sudden loading events, shedding
light on their resilience and survivability in adverse scenarios. Furthermore,

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environmental testing is employed to assess the performance of lattice structures
under extreme conditions, including temperature fluctuations, humidity,
corrosion, and exposure to harsh chemicals or environmental stressors.

These tests provide crucial data on the long-term durability and stability
of lattice structures, ensuring their suitability for deployment in demanding
operational environments. Throughout the testing process, data acquisition and
analysis play a pivotal role, enabling engineers to extract valuable insights,
identify performance trends, and refine design parameters iteratively. Advanced
computational tools and simulation techniques complement experimental
testing, offering predictive insights into the behavior of lattice structures and
guiding optimization efforts.

Interdisciplinary collaboration and cross-functional expertise are

paramount during testing, fostering synergies between materials science,
structural engineering, and experimental mechanics to achieve holistic
understanding and validation of lattice structures. In conclusion, lattice testing
represents a critical juncture in the development and validation of lattice
structures, where theoretical concepts are translated into practical solutions
through rigorous experimentation and analysis. By subjecting lattice structures
to a battery of tests encompassing material characterization, structural
validation, performance evaluation, and environmental testing, engineers gain
confidence in their performance, reliability, and suitability for diverse
engineering applications. As industries continue to embrace the transformative
potential of lattice structures, robust testing protocols will remain indispensable
for ensuring their integrity, safety, and efficacy in the face of evolving
challenges and demands.

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 CHAPTER 2

LITERATURE SURVEY

2.1 ENERGY ABSORBTION

Xiaoyang Liua, et. al (2020) investigated the formation mechanism of

shearband in metallic lattice structures using an Al-12Si alloy structure. X-ray
computed tomography and finite element analyses reveal crack initiations
trigger shear band formation. Finite element analyses show relaxed tensile stress
inside struts with controlled diameter ratios, suggesting suppressed shearband
formation. This provides new insights for achieving stable compressive
deformation and high energy absorption capacity.

ZakiAlomar, et. al (2021) developed the Metal Additive Manufacturing

(MAM) technology was used to design a new lattice structure made of Ti6Al4V
with a circular cell, demonstrating even stress distribution, higher load-bearing
capacity, and significant stress recovery.

Babamiri, et. al (2021) has investigated post-yield mechanical behavior of

additively manufactured lattice structures (AMLS) is influenced by the
interaction between intrinsic and extrinsic properties at different length scales.
A new design optimization approach accounts for scale separation and size
effects to achieve targeted macroscopic mechanical response. The approach
finds a correlation between local stresses within struts and underlying
microstructures, allowing for accurate representation of local stress states. The
interplay between topology and microstructure is assessed through finite
element simulations, leading to new topologies with 40% and 72%
improvement in energy absorption capacity and flow stress compared to
constitutive models.

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 Peng Wang, et. al (2021) was developed a lattice structure for energy
absorption, modified from the traditional face-centered cubic (FCC) lattice. The
structure has larger plateau stress and better energy absorption performance than
the traditional FCC structure. The study uses theoretical modeling, numerical
simulation, and experimental tests, revealing that the proposed lattice structures
have larger energy absorption capacity and auxetic and zero-Poisson effects.

Kwang-Min Park, et. al (2021) investigated the design process for lattice
structures and develop a lattice structure characterization database. It was
conducted on 11 types of unit cell-based lattice structures with dimensions of 20
mm × 20 mm × 20 mm. Results showed that simple cubic, octahedron,
truncated cube, and truncated octahedron-based lattice structures with a 3 × 3 ×
3 array pattern showed the best axial compressive strength properties under the
same relative density conditions. The study also identified correlations among
unit cell types, lattice structure topologies, relative densities, unit cell array
patterns, and mechanical properties.

Wenjin Tao, et. al (2016) developed the Additive Manufacturing (AM)

technology allows for the automatic fabrication of complex parts with advanced
shapes and architectures, enhancing design flexibility and application
opportunities. The lattice structure, which integrates multiple functions, is
particularly attractive due to its superior properties. This paper reviews AM
processes, design methods, mechanical behavior, and applications for lattice
structures.

Galarreta, et. al (2020) investigated the presents a method for performing

Finite Element Analysis (FEA) on lattice structures, focusing on the mechanical
properties of porous structures. The method involves analyzing inputs like
modelling type, element size, number of unit cells, boundary conditions, and

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material model. The results show good agreement with experimental results,
with an average error of around 10% and 17% for modulus and yield strength.

Hanfeng Yin, et. al (2023) investigated on energy absorption characteristics

of lattice structures, focusing on their performance evaluation indexes and
loading conditions. The structures are classified into 2D and 3D types, with
different types including general, auxetic, and hierarchical. The paper also
discusses the energy absorption properties of these structures, their fabrication
process, and engineering applications. It predicts future research directions,
providing a platform for researchers and engineers to design energy-absorbed
lattice structures and develop new structures.

Zuhal Ozdemir, et. al (2016) developed the significance of lattice structures

in porous engineering, emphasizing their exceptional energy absorption and
lightweight properties. It reviews recent research on their energy absorption
characteristics, classification into 2D and 3D structures, and detailed
descriptions of their properties. It also discusses fabrication processes,
engineering applications, and predicts future research directions, offering a
valuable resource for designing efficient lattice structures.

Divya .T, et. al (2021) developed the Cerium oxide demonstrates high
potential for chemical transformations in environmental and energy contexts.
This study analyzes how hydrothermal conditions affect the physicochemical
properties of cerium oxide synthesized from salt solution via ammonia
precipitation. The characterization involves SEM, TEM, XRD,
photoluminescence, Raman, TPR, and XPS analyses. Results show that
hydrothermal synthesis produces larger, more crystalline particles with
enhanced catalytic activity, attributed to increased lattice defects facilitating
redox reactions.

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 Hanfeng Yin, et. al (2023) developed a Porous and multi-cell structures,
particularly lattice structures, are pivotal in engineering for their remarkable
energy absorption and lightweight properties. This paper reviews recent
research on lattice structures' energy absorption characteristics, covering
performance evaluation, classification, energy absorption properties,
fabrication, engineering applications, and future research directions. It serves as
a valuable resource for designing and developing innovative lattice structures
for energy absorption.

2.2 LATTICES DESIGN

Mirhan Ozdemir et. al (2023) investigated on hybrid optimization scheme

combining genetic algorithms (GA) and anisotropic homogenization-based
topology optimization to enhance triply periodic minimum surfaces (TPMS)
lattice structures for Messerschmitt–Bölkow–Blohm (MBB) beam design. GAs
identify optimal lattice morphologies (Diamond, Gyroid, I-WP, Primitive) and
densities before topology optimization (TO). The TO further improves design
performance by grading the multi-morphology lattice. A novel blending
algorithm reconstructs the graded structure, which is manufactured using direct
metal laser melting (DMLM). Experimental results demonstrate 4.5% and
13.0% stiffness improvements over single lattice morphologies, highlighting the
effectiveness of the hybrid approach.

Chi Wu et. al (2023) investigated on multiscale topology optimization

method for additively manufactured lattice structures, utilizing a derivative-
aware machine learning algorithm. The goal is to optimize non-uniform unit
cells to achieve uniform strain patterns, particularly beneficial for biomedical
implants. Validation through digital image correlation (DIC) tests on fabricated
samples confirms effectiveness. Practical applications include bone tissue
scaffolds for musculoskeletal reconstruction, showcasing improved

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biomechanical environments for enhanced bone formation. This approach marks
a significant advancement in designing complex lattice structures with desired
mechanical properties, promising widespread applications in various fields,
particularly in biomedicine.

Tian Han et. al (2024) investigated on generative design to propose

modified lattice structures optimized for both tensile and compressive loading.
Variations of body-centered cubic (BCC) with parallel or crossed struts are
examined for manufacturability and performance. AlSi10Mg samples are
fabricated using selective laser melting (SLM), with SEM analysis confirming
surface morphology. Quasi-static compressive testing and finite element
modeling validate improved load-bearing and energy absorption capabilities.
The proposed structures, especially P-BCCXYZ, exhibit promising potential for
diverse load-bearing applications.

Iasef Md Rian (2023) explores the structural potential of Chinese ice-ray

(IR) lattices, traditionally used as decorative elements in Chinese window
design. It investigates the geometric qualities and develops an algorithm for
modeling IR lattice patterns for shell design. The research compares the
structural effectiveness of IR lattice shells to conventional gridshells and
explores the feasibility of digital fabrication for constructing these lattice shells.
By leveraging fractal geometry, the study introduces a new structural
morphology, highlighting the potential of stochastic patterns in lattice shell
design for innovative structural applications.

Wahyudin P. Syam a Wu Jianwei, et. al (2018) developed the strut-based

lattice structures designed to enhance machine frame vibration isolation while
maintaining structural integrity. It introduces design parameters correlating
lattices to natural frequency and strength, crucial for efficient vibration
isolation. Computational parameters like total area moment of inertia and mass

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aid selection, validated through finite element modeling and experimental
testing via laser powder bed fusion.

Jiaqi Zhao, et. al (2019) investigated on concurrent design approach for

Additive Manufacturing (AM) fabricated lattice structures, optimizing natural
frequencies. It integrates void units for improved frequency objectives,
considering process limitations like Minimum Feature Size and self-supporting
constraints. A concurrent optimization model optimizes unit density layout and
part orientation, achieving high-quality solutions with low computational costs.
Experimentally validated, structures designed this way exhibit higher
fundamental frequencies.

Jozef Tkac, et. al (2020) developed the mechanical properties of 3D printed

lattice structures depend on material properties and topology. Experimental and
FE modeling are essential for macroscopic understanding. Damage
identification and deformation analysis treat lattice as porous. PTC Creo 6 CAD
software was used for 3D modeling, enabling physical realization and export to
Abaqus for simulations. Uniaxial compression tests determined material
models, while damage evolution was described using a scalar parameter.

Nan Jin, et. al (2019) developed the dynamic behavior of diamond (Dfcc,
Dhex), face-centered cubic (FCC), and body-centered cubic (BCC) lattice
structures manufactured via selective laser melting. Failure initiation differs
between structures. FCC and BCC primarily undergo stretching and bending
respectively, while Dfcc and Dhex combine both. Mechanical properties,
described by a power law function, reveal FCC's superiority in specific strength,
modulus, and energy absorption, indicating stretching-dominated deformation's
advantage under dynamic loading.

Maskery .I, et. al (2018) investigates surface-based lattice structures for

additive manufacturing design, providing surface equations and demonstrating

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volume fraction tailoring. Finite element analysis explores cell type, orientation,
and volume fraction effects on elastic moduli, aiding stiffness specification. The
I-WP lattice in [001] orientation offers highest stiffness uniaxially, while
diamond lattice suits lower mechanical anisotropy needs. Stiffness models aid
graded structure prediction, addressing structural weakening in hybridized
lattice types with a novel solution.

2.3 SHAPE OPTIMIZATION

Long Chen, et. al (2024) developed the proposes a volume parametric

modeling method for lattice structures and an efficient multiscale topology
optimization framework using isogeometric analysis (IGA). A skeleton model
accurately describes topology, enhancing data utilization and computational
efficiency. Multiscale optimization adjusts control point density, enabling
integrated design of lattice structure modeling, simulation, and optimization.
Verified through mechanical parts, gradient lattice structures exhibit superior
strength and stress distribution.

Fabian Günther, et. al (2013) developed shape optimization of triply

periodic minimal surface (TPMS) based lattice structures for bone substitutes
using additive manufacturing. Various load cases are considered, and optimized
lattices are manufactured from Ti-42Nb alloy and tested under compression.
Results show significant stiffness and strength improvements while preserving
TPMS morphology, indicating potential for future implant applications.

Arash Armanfar, et. al (2024) investigated on Additive manufacturing (AM)

has been making inroads into the shipbuilding industry. The maritime sector has
recognized the potential benefits of AM in terms of cost savings, design
flexibility, and rapid prototyping. Lattice structures, known for their vast
applications in AM and associated benefits like lightweight design, energy
efficiency, and improved material usage, serve as a focal point in this shifting

15
landscape. This paper presents a pioneering approach to integrating lattice
structures into shipbuilding via AM, specifically for supporting ship volumes.
The method introduces algorithms to create both conformal and uniform lattice
structures for structural optimization. According to the case studies in this work,
ship models with lattice structures have superior structural properties compared
to conventional support elements.

Ming Li, et. al (2023) investigated on proposes an optimization method for

designing multi-lattice structures meeting local buckling constraints. It employs
a consecutive numerical approach involving macro-field optimization and
microstructure embedding. A machine learning approach reduces computational
costs. The method optimizes overall stiffness and local buckling resistance,
demonstrated through numerical examples.

Jingwei Zhang, et. al (2023) developed a integrates material anisotropy and

geometric errors induced by additive manufacturing (AM) into topology
optimization for fiber-reinforced polymer lattice structures. Material properties
of 3D printed carbon fiber-reinforced polymers (CFRP) were investigated via
tensile tests and digital image correlation. Accurate orthotropic material models
were applied to unit lattices with geometric errors, optimizing mechanical
performance of macroscale structures. Considering microscale material
anisotropy and mesoscale geometric errors improves optimization accuracy and
reliability.

Neil R. Avery (1982) investigated the adsorption of HCOOH on Pt(111) and

Pt(111)-O surfaces has been studied by high resolution electron energy loss
spectroscopy and thermal reaction desorption spectroscopy. At 130 K,
multilayer HCOOH is molecularly adsorbed in the strongly hydrogen-bonded α-
polymorphic form which evaporates at 170 K, leaving a bridge-bonded formate
species in the highly symmetric C2v configuration. Preadsorbed oxygen

16
enhances the Bronsted basicity of the Pt(111) surface, raising the yield of
formate six- to seven-fold. Reaction with the Pt(111)-O surface produced H2O
which desorbed at 180 K. Formate decomposition occurred exclusively by
dehydrogenation to H2 + CO2 at 260 K. No evidence for any other
decomposition products was found.

Zhendong Yang et. al (2024) investigated efficient and exquisite concurrent

optimization of hierarchical structures with non-uniform eccentric body
centered cubic lattice. This study introduces a novel optimization method for
designing lightweight yet robust micro lattices and hierarchical structures. It
combines precise inverse design techniques for micro lattices with density-
based topology optimization for macro structures. The approach, utilizing
Parameterized Interpolation for Anisotropic Lattice material (PIAL), enhances
computational efficiency. Additive Manufacturing with AlSi10Mg validates the
method, showing improved mechanical performance over conventional density-
graded structures.

Zhengtao Shu (2024) investigated the multivariable level set-based topology

optimization approach for designing graded lattice structures (GLSs)
considering diverse microstructure prototypes and geometric continuity. Using
signed distance functions, basic level set functions (LSFs) for implicit and
designable microstructures are created, with weight coefficients generating
GLSs. Sub-GLSs corresponding to predefined microstructure prototypes are
optimized, ensuring perfect geometric connections. This strategy expands
design space and enhances performance, demonstrated through 2D and 3D
examples.

Logesh Kothandaraman (2024) investigates the integration of square lattice

structures in Fused Deposition Modeling (FDM) using Polylactic Acid (PLA)
filament. Taguchi optimization optimizes printing parameters, focusing on

17
weight-strength ratio enhancement. L9 orthogonal array experiments consider
layer height, printing temperature, and speed. Optimal parameters yield a 25.4%
tensile strength improvement. The research improves productivity, material
usage, relevant to automotive and medical industries seeking lightweight,
durable products.

Shahram Hosseini et.al (2023) explores the compressive nonlinear response

of a sinusoidal shape memory unit cell made of PLA. Various architectures are
optimized via finite element analysis, and the data is used to train an artificial
neural network. Experimental tests confirm the structure's ability to return to its
original shape after exposure to heat, with decreasing energy absorption and
peak force over multiple cycles. The proposed structure shows promise as an
energy absorber with repeatable mechanical properties.

2.4 LATTICES TESTING

Jonathan Pearl, et. al (2023) investigated the Plasma facing components'

performance is assessed in high-heat flux conditions. A novel limiter mock-up
underwent cyclic thermal loading at the UKAEA's HIVE facility. Results
showcased HIVE's capability and the mock-up's performance. The mock-up,
comprising additively manufactured Tungsten-Tantalum lattice brazed to a
copper heat sink, endured heat fluxes up to 10 MW/m2. Visual inspection
revealed lattice cracking, prompting preliminary electromagnetic analysis for
further insight.

Fabrizia Caiazzo, et. al (2022) investigates steel functionally graded strut-

based lattice structures via additive manufacturing. Mechanical properties are
mapped based on grading approach (uniform, size-graded, rod-graded) and
fractional density (15%, 25%, 35%). Results reveal strut distortion in low-
density samples and deviations in rod-graded structures. Size-graded designs
exhibit superior mechanical properties independent of fractional density.

18
 Junfang Zhang, et. al (2022) considered to be one of the key factors
affecting the structural properties of porous lattices, but in fact, pore size also
plays an important role, and it has great potential to adjust pore size and
porosity independently to improve structural properties. In this work, by
adjusting the sheet thickness of the triply periodic minimal surface (TPMS)
lattice structures and adjusting the height of the single row structure according
to linear and constant laws, the TPMS lattice structures with given porosity and
adjustable pore size are designed, and the mechanical response is investigated.
Based on preparing samples by Ti6Al4V laser powder bed fusion, the results of
the tests show that the elastic modulus ranges of linear change TPMS (LC-
TPMS) and constant TPMS (C-TPMS) lattice structures are 3625.6 MPa–
4575.1 MPa and 3820.0 MPa–4509.1 MPa, respectively. In the plateau stage,
the LC-TPMS lattice structures have a longer and more stable plateau stage,
higher yield stress and better energy absorption capacity than the C-TPMS
lattice structures. The maximum energy absorption difference is 62.7 MJ/mm3
and the maximum energy absorption efficiency difference is 0.12. The LC-
TPMS lattice structures can also obtain a larger damping ratio under larger
compressive strain.

Ibrahim .Y, et. al (2018) to developed the Additive manufacturing (AM)

allows engineers to design and manufacture complex weight saving lattice
structures with relative ease. These structures, however, present a challenge for
inspection. A non-destructive testing and evaluation method used to assess
material properties and quality is the focus of this paper, namely acoustic
resonance (AR) testing. For this research, AR testing was conducted on weight
saving lattice structures (fine and coarse) manufactured by powder bed fusion.
The suitability of AR testing was assessed through a combined approach of
experimental testing and FE modelling. A sensitivity study was conducted on
the FE model to quantify the influence of element coarseness on the resonant

19
frequency prediction and this needs to be taken into account in the application
and analysis of the technique. The analysis was extended to extract effective
modulus values for the lattice structures and the solid materials from every
detected overtone, allowing for multiple measurements from a single AR test
without the need to carefully isolate the fundamental. The AR and FE modelling
modulus of elasticity values were validated using specimens of known
properties. There was fair agreement between the FE and compression test
extracted values of effective modulus for the coarse lattice. For the fine lattice,
there was agreement in the values of effective modulus extracted from AR, 3-
point bend, and compression experimental tests carried out. It was found that
loose powder fusing from AM resulted in the fine lattice structure having a
higher density (at least 1.5 times greater) than calculated due to the effect of
loose powder adhesion. This effect resulted in an increased stiffness of the fine
lattice structure. AR can be used as a measure of determining loose powder
adhesion and other unique structural characteristics resulting from AM.

Phill-Seung Lee, et. al (2007) develop a numerical model for simulating

ultimate behavior of lattice steel tower structures. We present the elastoplastic
large deformation analysis of a lattice steel tower structure using finite element
analysis and we compare the numerical results with full-scale destructive tests.
A 2-node three-dimensional L-section beam finite element proposed in our
previous work is used. The beam finite element can consider eccentricities of
loading and boundary conditions as well as material and geometrical
nonlinearities. We model a real tower structure section using the beam elements
and perform a nonlinear static analysis to obtain the limit behavior of the tower
in two different load cases. The numerical results are discussed in detail.

20
2.5 OBSERVATION:

Heat dissipation emerges as a significant challenge that demands

attention and innovation. Currently, foam materials, commonly utilized for
cushioning purposes, exhibit limitations in their ability to effectively dissipate
heat due to their inherent properties. One prominent issue lies in the lack of
uniform structure within foam materials, leading to uneven heat distribution and
potential discomfort for users, particularly during prolonged periods of use.
Moreover, the existing solutions predominantly cater to adult users, thereby
restricting their widespread applicability across diverse age groups and
applications. However, the imperative for effective cushioning remains
paramount across various industries, necessitating proactive measures to
address these challenges and enhance user experience. To mitigate the
challenges associated with heat dissipation in cushioning materials, innovative
solutions are warranted.

One avenue for improvement lies in advancing technologies aimed at

enhancing heat dissipation capabilities within cushioning materials. By
integrating heat-dissipating elements or incorporating novel materials with
superior thermal conductivity properties, manufacturers can significantly
improve the thermal management performance of cushioning materials.
Furthermore, optimizing the structure and composition of foam materials to
achieve a more uniform cellular arrangement can contribute to more efficient
heat dissipation, thereby enhancing user comfort and reducing the risk of
overheating. Additionally, expanding the range of cushioning solutions to cater
to diverse age groups and specific application requirements is essential for
addressing the limitations of current offerings. Designing specialized
cushioning materials tailored to the unique needs of infants, children, elderly
individuals, and individuals with specific medical conditions can ensure broader
accessibility and usability across various demographic segments. Moreover,

21
advancements in cushioning technology can extend beyond traditional
applications in consumer products to encompass specialized sectors such as
sports equipment, healthcare devices, and automotive interiors, where superior
cushioning performance is paramount.

In the sports industry, for instance, innovative cushioning materials can

enhance the comfort, support, and injury prevention capabilities of athletic
footwear, thereby improving the overall performance and well-being of athletes.
Similarly, in the healthcare sector, advanced cushioning materials can play a
crucial role in the development of orthopedic devices, medical mattresses, and
seating solutions, providing optimal support and pressure relief for patients with
mobility issues or chronic conditions. Furthermore, within the automotive
sector, the integration of advanced cushioning materials in vehicle interiors can
enhance passenger comfort and safety by mitigating the impact of vibrations
and sudden jolts during transit.

In conclusion, addressing the challenges associated with heat dissipation

and expanding the range of cushioning solutions represent critical objectives for
innovation in the field of materials science and engineering. By leveraging
advancements in heat dissipation technology, optimizing foam structure
uniformity, and diversifying product offerings to cater to various age groups and
industries, manufacturers can elevate the performance, comfort, and safety
standards of cushioning materials across diverse applications. Through
collaborative efforts and continuous innovation, the potential benefits of
enhanced cushioning solutions extend across industries, promising improved
user experiences and enhanced product performance in the years to come.

22
 CHAPTER 3

MATERIALS

3.1 THERMOPLASTIC POLYURETHANE (TPU)

TPU, lauded for its flexibility, robust tensile strength, and resistance to
tears and abrasions, reigns supreme in 3D printing for its capacity to produce
flexible parts. Its versatility finds extensive applications across consumer
products and industrial sectors, where its exceptional material properties are
indispensable. As a preferred choice for crafting a diverse range of components,
TPU stands at the forefront of modern manufacturing proce
processes,
sses, offering
unparalleled reliability and performance. Its widespread adoption underscores
its pivotal role in driving innovation and meeting the evolving demands of
various industries, cementing its position as a cornerstone material in additive
manufacturing
turing technologies.

Figure 3.1
.1 Thermoplastic Polyurethane (TPU)

23
3.2 NYLON

Nylon, renowned for its durability, strength, and versatility, emerges as a

quintessential material in various industries. Its exceptional mechanical
properties make it a favored choice for producing a diverse array of
components, ranging from automotive parts to consumer goods. With its high
tensile strength and resistance to wear and tear, nylon stands as a cornerstone
material for manufacturing applications demanding rel
reliability
iability and longevity. Its
chemical resistance and thermal stability further enhance its suitability for
diverse environments and operating conditions. Embraced for its resilience and
adaptability, nylon continues to play a pivotal role in driving innovat
innovation and
addressing the evolving needs of modern manufacturing processes.

Figure 3.2 Nylon

24
3.3 POLYPROPYLENE (PP)

Polypropylene (PP) stands as a ubiquitous thermoplastic, widely

embraced across industries worldwide for its versatility and practicality. Its
applications span from plastic packaging to machinery and equipment
components, showcasing its adaptability in various sectors. PP's usage extends
further into fibres and textiles, underscoring its utility in everyday products.
Renowned for its lightweight,
eight, durability, and chemical resistance, PP proves
indispensable in modern manufacturing. Its affordability and ease of processing
further enhance its appeal, making it a material of choice for diverse
applications. With its extensive practical use and unmatched versatility, PP
continues to shape the landscape of industries, driving innovation and meeting
evolving demands.

Figure 3.3 Polypropylene (PP)

25
3.4 OBSERVATION

The objective is to assess TPU's practical suitability for 3D printing

applications compared to Nylon and Polypropylene (PP). Evaluation will focus
on TPU's material properties such as flexibility, tensile strength, tear resistance,
and abrasion resistance, determining its efficacy for producing flexible parts in
consumer products
ducts and industrial components.

3.5 WHY TPU?

TPU, or Thermoplastic Polyurethane, is favored for its outstanding

flexibility, robust tensile strength, and resistance to tears and abrasions, making
it ideal for 3D printing flexible parts. Its versatility and durability suit various
applications in consumer products and industrial parts, where flexibility and
resilience are paramount. TPU's performance characteristics position it as a
preferred choice for meeting functional and aesthetic requirements in additive
add
manufacturing. Its ability to maintain structural integrity under stress, alongside
its capacity for intricate designs, underscores its versatility and reliability across
diverse industries, cementing its status as a cornerstone material in modern
manufacturing processes.

Figure 3.5 why TPU?

26
 CHAPTER 4

PROCESS PLANNING

Conceptualization and survey

Design Development

Prototyping

Testing and Evaluation

Design Refinement

Product

Figure 4.1 Process Planning

27
4.1 CONCEPTUALIZATION AND SURVEY

constitute the foundational phase in product development, encompassing

a multifaceted approach to define the purpose, functionality, and constraints of
the product. This stage commences with a thorough understanding of user
needs, market demands, and technical specifications. Surveys, interviews, and
market analyses are conducted to gather insights into consumer preferences,
emerging trends, and technological advancements. This iterative process fosters
creativity and exploration, generating multiple concepts to address identified
needs and opportunities. Each concept is meticulously evaluated for technical
feasibility, cost-effectiveness, and resource requirements. Through rigorous
analysis, promising concepts are identified based on performance,
manufacturability, market potential, and alignment with project goals. The
outcome of this phase is a refined set of concept designs, poised to advance to
the subsequent stages of development. By adhering to a structured approach,
designers ensure that the chosen concepts not only meet user expectations but
also align with market dynamics and project objectives. This comprehensive
methodology lays the groundwork for successful product development, setting
the stage for the realization of innovative solutions tailored to address identified
needs and opportunities.

4.2 DESIGN DEVELOPMENT

In the design development phase, detailed designs of the selected

concepts are meticulously crafted using Computer-Aided Design (CAD)
software. This involves creating comprehensive 2D sketches, intricate 3D
models, and precise assembly drawings, laying the groundwork for the
realization of the envisioned product. Simultaneously, appropriate materials are
judiciously chosen based on the design requirements, considering factors such
as strength, durability, cost-effectiveness, and manufacturability. Material

28
selection plays a pivotal role in determining the performance and reliability of
the final product. Moreover, the identification of suitable manufacturing
processes is paramount, accounting for the complexity of the design, desired
material properties, and production volume. Whether it be injection molding,
machining, or 3D printing, the chosen manufacturing method must align with
the project's objectives and constraints. Validation of the design is ensured
through the utilization of simulation tools and prototypes. By subjecting the
design to rigorous testing, engineers verify its compliance with performance
criteria, safety standards, and regulatory requirements, thus mitigating potential
risks and enhancing overall quality. Additionally, estimating the manufacturing
cost of the design is imperative, encompassing material costs, labor costs,
tooling expenses, and overheads. This comprehensive cost analysis facilitates
informed decision-making and ensures the feasibility and viability of the design
within budgetary constraints.

4.3 PROTOTYPE

Build prototypes of the selected design are constructed using either rapid
prototyping techniques or traditional manufacturing methods. This process may
involve in-house prototyping or outsourcing to specialized facilities, depending
on resources and expertise. A comprehensive testing plan is developed to
evaluate the performance, functionality, and reliability of the prototypes. This
plan includes defining test scenarios, acceptance criteria, and measurement
methods to ensure thorough assessment. Rigorous testing of the prototypes is
conducted under various conditions, encompassing simulated use cases,
environmental factors, and stress tests. Data collected from these tests is
meticulously analyzed to identify strengths, weaknesses, and areas for
improvement. Furthermore, feedback is gathered from stakeholders, including
users, engineers, and domain experts. Their input is invaluable in refining the
design and addressing any identified issues. By incorporating stakeholder

29
feedback, engineers can iteratively refine the prototype, ensuring that it meets
the desired performance objectives and user requirements. Overall, the
prototype phase serves as a crucial step in the product development process,
allowing engineers to validate the design, assess performance, and gather
valuable insights for refinement. This iterative approach ensures that the final
product meets or exceeds expectations, delivering optimal performance and user
satisfaction.

4.4 TESTING AND EVALUATION

Conduct thorough performance testing of the prototypes is conducted to

assess various factors including durability, reliability, efficiency, and safety.
This involves subjecting the prototypes to rigorous testing under simulated real-
world conditions to identify any potential weaknesses or areas for improvement.
Additionally, feedback is solicited from end-users through surveys, interviews,
and usability testing. This feedback provides valuable insights into user
satisfaction, ease of use, and overall user experience, helping to refine the
design to better meet user needs and expectations. Furthermore, compliance
with relevant industry standards, regulations, and certification requirements is
ensured through comprehensive testing and inspections. This includes verifying
conformity to applicable standards to guarantee product quality and safety.
Based on testing results and stakeholder feedback, the design is iteratively
refined to address any deficiencies or areas of concern. Design modifications
are implemented to improve performance, usability, and safety, ensuring that
the final product meets or exceeds both regulatory requirements and user
expectations. Overall, the testing and evaluation phase is essential for ensuring
the quality, safety, and usability of the product. By systematically testing and
gathering feedback, engineers can iteratively refine the design to create a
product that meets the highest standards of performance, reliability, and user
satisfaction.

30
4.5 DESIGN REFINEMENT

Continuously refining the design based on insights from testing and

evaluation is fundamental to the product development process. Incorporating
feedback from stakeholders ensures iterative improvements, optimizing
performance, cost-effectiveness, manufacturability, and user satisfaction.
Techniques such as value engineering, design for manufacturability, and design
for assembly are utilized to streamline processes and enhance efficiency.
Identifying and mitigating potential risks associated with the design,
manufacturing process, and product usage is essential. Implementing risk
mitigation strategies enhances product reliability and safety, safeguarding
against unforeseen issues. Documenting all design changes, test results, and
lessons learned throughout the refinement process is critical. Maintaining clear
and comprehensive records enables traceability and accountability, facilitating
future iterations and product lifecycle management. It ensures that insights
gained from each stage are preserved and leveraged for continuous
improvement, ultimately contributing to the development of high-quality
products that meet user needs and exceed expectations.

4.6 PRODUCT

Finalizing the design based on the refined prototype and testing outcomes
marks a critical juncture in the product development process. Ensuring all
design requirements and specifications are met, engineers meticulously develop
a production plan outlining manufacturing processes, resource allocation,
scheduling, and quality control procedures. Commencing mass production of
the product using chosen manufacturing processes follows, with close
monitoring of production quality and performance to maintain consistency and
meet production targets. Implementing rigorous quality assurance measures
verifies product conformance to specifications and standards, ensuring

31
uncompromised quality throughout. Conducting inspections, audits, and quality
control checks throughout the manufacturing process further bolsters quality
assurance efforts. Upon completion, the product is launched into the market
through appropriate distribution channels. Developing marketing strategies and
promotional campaigns plays a pivotal role in generating awareness and driving
sales, leveraging the product's unique features and benefits. Providing
comprehensive customer support, warranty services, and product maintenance
post-launch ensures customer satisfaction and product longevity, fostering
lasting relationships and building brand loyalty. This comprehensive approach
ensures that the product not only meets but exceeds customer expectations,
establishing a strong presence in the market.

32
 CHAPTER 5

METHODOLOGY

Problem Statement

Conceptualization

Material Selection

Steam Design

Head Design

Unit cell Design

Assemble

Evaluation

Figure 5.1 Methodology

33
5.1 MATERIAL SELECTION:

Material selection for lattice structure fabrication is a critical aspect of the

design process, influencing the performance, durability, and cost-effectiveness
of the final product. Engineers embark on a meticulous journey to identify and
evaluate suitable materials based on a myriad of considerations, ranging from
mechanical properties to manufacturing feasibility. At the heart of this endeavor
lies the need to strike a delicate balance between competing factors such as
strength, weight, cost, and processability, ensuring that the chosen materials
align closely with the desired performance objectives and design constraints.

One of the primary considerations in material selection is mechanical

properties, encompassing parameters such as tensile strength, modulus of
elasticity, and ductility. These properties dictate the structural integrity and
load-bearing capacity of lattice structures, influencing their ability to withstand
external forces and maintain dimensional stability under varying conditions.
Through comprehensive material testing, engineers meticulously assess the
mechanical behavior of candidate materials, subjecting them to a battery of tests
to characterize their performance across a spectrum of loading scenarios. By
analyzing stress-strain curves, fracture toughness, and fatigue behavior,
engineers gain valuable insights into the material's response to mechanical
stimuli, enabling informed decisions in material selection.

In addition to mechanical properties, weight plays a pivotal role in

material selection for lattice structures, particularly in applications where
lightweight construction is paramount, such as aerospace and automotive
engineering. Lightweight materials offer significant advantages in terms of fuel
efficiency, maneuverability, and overall performance, making them highly
desirable for these industries. By opting for lightweight materials with high
strength-to-weight ratios, engineers can achieve substantial weight savings

34
without compromising structural integrity, thereby enhancing the overall
efficiency and competitiveness of the final product.

Cost considerations also feature prominently in material selection, as the

choice of materials can have significant implications for the overall project
budget and economic viability. Engineers must strike a judicious balance
between material cost and performance, opting for materials that offer the best
combination of affordability and functionality. While advanced materials may
boast superior mechanical properties, they often come with a higher price tag,
necessitating careful evaluation of cost-benefit trade-offs. Through cost analysis
and value engineering exercises, engineers can identify cost-effective
alternatives that meet performance requirements without exceeding budgetary
constraints.

Manufacturing feasibility is another crucial factor influencing material

selection, as engineers must ensure that the chosen materials are compatible
with the selected manufacturing processes and techniques. Different materials
exhibit varying degrees of processability, with some being more amenable to
conventional machining, casting, or molding processes, while others are better
suited for advanced manufacturing methods like additive manufacturing (AM)
or 3D printing. By aligning material selection with manufacturing capabilities,
engineers can streamline production workflows, minimize production costs, and
accelerate time-to-market for lattice structures.

Overall, material selection for lattice structure fabrication is a

multifaceted endeavor that requires careful consideration of mechanical
properties, weight, cost, and manufacturing feasibility. Through rigorous
material testing, cost analysis, and process compatibility assessments, engineers
can identify and procure materials that best meet the performance requirements
and design objectives of their projects. By adopting a systematic and informed

35
approach to material selection, engineers can ensure the optimal performance,
reliability, and cost-effectiveness of lattice structures across a diverse range of
applications, from aerospace components to medical implants and beyond.

5.2 LATTICE STRUCTURE DESIGN:

Lattice structure design is a multifaceted process that involves

conceptualization, parameter optimization, and precise modeling to create
structures with exceptional mechanical properties and tailored functionalities.
At the outset, engineers embark on the journey of conceptualizing appropriate
geometries that align closely with the specific requirements and performance
criteria of the intended application. Key parameters such as cell size, strut
thickness, and overall dimensions are meticulously determined, taking into
account factors such as load-bearing capacity, structural stability, and
manufacturability. These parameters serve as the building blocks for the design,
laying the foundation for the creation of robust and efficient lattice structures.

Central to the design process is the utilization of Computer-Aided Design

(CAD) software, which serves as a powerful tool for creating detailed models of
lattice structures with precision and accuracy. CAD software enables engineers
to translate conceptual designs into tangible virtual models, providing a
platform for visualization, analysis, and optimization. By leveraging advanced
modeling capabilities, engineers can explore a myriad of design iterations, fine-
tuning parameters to achieve optimal performance and functionality. This
iterative approach allows for the refinement of lattice structures to meet
stringent design objectives while ensuring compliance with technical
specifications and performance standards.

The systematic application of CAD tools facilitates the exploration of

design variations and the evaluation of design alternatives, enabling engineers
to make informed decisions throughout the design process. Through rigorous

36
analysis and simulation, engineers can assess the structural integrity,
mechanical behavior, and performance characteristics of lattice structures under
various loading conditions. This comprehensive analysis aids in identifying
potential design flaws, optimizing structural configurations, and mitigating risks
associated with structural failure or performance degradation.

Furthermore, CAD software enables engineers to integrate additional

design features and functionalities into lattice structures, enhancing their
versatility and adaptability for diverse applications. Whether it be in aerospace,
automotive, or medical applications, lattice structures can be tailored to meet the
demands of modern engineering challenges, offering lightweight, durable, and
customizable solutions to complex design problems. From optimizing load
distribution to enhancing energy absorption capabilities, CAD-driven design
processes empower engineers to push the boundaries of innovation and create
structures that excel in performance, efficiency, and reliability.

In essence, lattice structure design represents a convergence of creativity,

precision, and technological prowess, guided by the principles of engineering
excellence and design optimization. By harnessing the capabilities of CAD
software and adopting a systematic approach to design, engineers can unlock
the full potential of lattice structures, unleashing new possibilities for
innovation and advancement in engineering practice. As technology continues
to evolve and new design paradigms emerge, the role of CAD-driven design
processes will remain instrumental in shaping the future of lattice structure
design, driving progress and innovation across a myriad of industries and
applications.

5.3 FINITE ELEMENT ANALYSIS (FEA):

Finite Element Analysis (FEA) stands as a cornerstone in the realm of

engineering, offering a powerful toolset for the comprehensive analysis and

37
optimization of lattice structures. At its core, FEA involves the intricate process
of importing Computer-Aided Design (CAD) models into specialized software
environments, where the geometrical intricacies and material properties of
lattice structures are meticulously defined and analyzed. This initial step sets the
stage for a meticulous exploration of the structural behavior and performance of
lattice structures under diverse loading conditions, ranging from static loads to
dynamic forces encountered in real-world scenarios.

Material properties play a pivotal role in FEA, as they directly influence

the mechanical response and behavior of lattice structures under load. Engineers
devote significant attention to accurately defining material properties such as
Young's modulus, Poisson's ratio, and yield strength, ensuring that the simulated
behavior closely mirrors real-world conditions. Additionally, boundary
conditions and loading scenarios are meticulously defined to replicate the
complex environmental factors and operational conditions encountered by
lattice structures in their intended applications. By subjecting lattice structures
to a battery of static and dynamic analyses, engineers gain invaluable insights
into critical performance metrics such as stress distribution, deformation
patterns, and energy absorption characteristics.

Through static analyses, engineers can evaluate the structural integrity

and load-bearing capacity of lattice structures under steady-state loading
conditions. This enables the identification of potential failure points, stress
concentrations, and areas of concern, informing design modifications and
optimization efforts. Meanwhile, dynamic analyses offer a glimpse into the
dynamic response of lattice structures under transient loading conditions, such
as impact or vibration. By simulating dynamic events and evaluating parameters
like natural frequencies, damping ratios, and mode shapes, engineers can assess
the structural robustness and resilience of lattice structures in dynamic
environments.

38
 FEA empowers engineers to conduct a comprehensive evaluation of
lattice structures, enabling them to make informed design decisions and
optimize structural performance. By scrutinizing stress distribution, deformation
patterns, and energy absorption characteristics, engineers can identify design
flaws, optimize structural configurations, and enhance performance metrics.
This iterative process of analysis and optimization facilitates the development of
lattice structures that meet stringent performance requirements across a diverse
array of applications.

Moreover, FEA serves as a vital tool for validating and verifying

computational models against experimental data, ensuring the accuracy and
reliability of simulation results. By comparing simulated outcomes with
empirical measurements obtained from physical testing, engineers can validate
the predictive capabilities of FEA models and gain confidence in their ability to
simulate real-world behavior accurately.

Finite Element Analysis (FEA) stands as a indispensable tool in the

arsenal of engineering, enabling the comprehensive analysis, optimization, and
validation of lattice structures. By leveraging FEA, engineers can gain
invaluable insights into the structural behavior and performance of lattice
structures, facilitating informed design decisions and optimization efforts. With
FEA, designers can ensure that lattice structures meet stringent performance
requirements across various applications, from structural components in
aerospace to protective gear in sports and beyond.

5.4 OPTIMIZATION:

Optimization stands as a fundamental pillar in the design and engineering

of lattice structures, providing a systematic framework for enhancing their
energy absorption performance and structural efficiency. At the heart of
optimization lie sophisticated algorithms such as topology optimization, which

39
enable engineers to iteratively refine lattice designs to achieve superior
performance metrics. The optimization process begins with the definition of
clear objectives and constraints, carefully tailored to the specific requirements
of the intended application. These objectives may encompass maximizing
specific energy absorption capacities, minimizing peak stresses, or optimizing
other performance criteria critical to the functionality and reliability of lattice
structures.

Through the utilization of optimization algorithms, engineers embark on a

journey of iterative refinement, exploring a vast design space to identify optimal
configurations that meet or exceed performance targets. Topology optimization,
for instance, enables designers to iteratively modify the internal geometry of
lattice structures, redistributing material to areas where it is most needed to
enhance energy absorption capabilities. By systematically exploring design
variations and evaluating their performance against predefined objectives and
constraints, engineers can uncover novel solutions that push the boundaries of
structural efficiency and performance.

Parametric studies further enrich the optimization process by enabling

engineers to examine the influence of individual design parameters on energy
absorption behavior. By systematically varying parameters such as cell size,
strut thickness, and overall geometry, engineers can gain valuable insights into
the sensitivity of lattice structures to design changes. This empirical
understanding empowers designers to make informed decisions during the
optimization process, fine-tuning design parameters to achieve optimal
performance while ensuring compliance with design constraints and
manufacturing considerations.

The iterative nature of optimization ensures that lattice structures evolve

over successive design iterations, gradually converging towards configurations

40
that exhibit superior energy absorption performance and structural integrity.
Through each iteration, engineers analyze and evaluate design variations,
leveraging insights gained from previous iterations to inform subsequent
refinements. This iterative feedback loop enables continuous improvement,
driving lattice structures towards ever-higher levels of performance and
efficiency.

Ultimately, systematic optimization ensures that lattice structures are

meticulously crafted to meet stringent performance criteria across diverse
applications. From enhancing crashworthiness in automotive components to
fortifying impact-resistant structures in aerospace, optimized lattice designs
excel in demanding real-world scenarios, delivering unparalleled levels of
structural efficiency and reliability. By pushing the forefront of engineering
innovation, optimization serves as a catalyst for advancements in structural
design, enabling engineers to unlock new possibilities and push the boundaries
of what is achievable in lattice structure engineering.

Optimization stands as a cornerstone in the design and engineering of

lattice structures, offering a systematic approach to enhancing their energy
absorption performance and structural efficiency. Through the application of
sophisticated algorithms and parametric studies, engineers iteratively refine
lattice designs, pushing the boundaries of structural innovation and unlocking
new possibilities for performance enhancement. By embracing systematic
optimization, designers ensure that lattice structures meet the rigorous demands
of diverse applications, driving forward the forefront of engineering excellence
and innovation.

5.5 ADDITIVE MANUFACTURING:

Additive Manufacturing (AM) revolutionizes the production landscape by

offering unprecedented flexibility and efficiency in fabricating complex lattice

41
structures. At the heart of this transformative technology lie sophisticated CAD
models meticulously tailored to suit specific AM processes such as Selective
Laser Sintering (SLS) or Fused Deposition Modeling (FDM). These CAD
models serve as blueprints, guiding the additive manufacturing process with
precision and accuracy. Key considerations in this process include the selection
of appropriate AM parameters, such as layer thickness and build orientation,
which play a pivotal role in optimizing the fabrication process for lattice
structure prototypes.

The intricate geometries and internal configurations characteristic of

lattice structures pose unique challenges and opportunities in the realm of
additive manufacturing. Leveraging the capabilities of AM, engineers can
translate these intricate designs into physical prototypes with unparalleled speed
and precision. SLS, for instance, employs a laser to selectively fuse powdered
materials, enabling the creation of intricate lattice structures layer by layer. On
the other hand, FDM utilizes a thermoplastic filament extrusion process to build
up structures, offering versatility and affordability in producing lattice
prototypes.

Careful consideration of AM parameters is essential to ensuring the

successful fabrication of lattice structures. Layer thickness, for example,
determines the resolution and surface finish of printed parts, with thinner layers
often yielding finer details and smoother surfaces. Similarly, optimizing build
orientation is crucial for minimizing support structures and reducing printing
time while maintaining structural integrity. By strategically orienting lattice
structures during printing, engineers can optimize material usage and minimize
post-processing requirements, enhancing overall manufacturing efficiency.

The adoption of AM in lattice structure fabrication unlocks a realm of

possibilities across a myriad of industries. In aerospace, where lightweight yet

42
robust components are paramount, AM enables the production of intricate
lattice structures that offer exceptional strength-to-weight ratios. In the medical
field, AM facilitates the creation of patient-specific implants with tailored lattice
geometries, optimizing biomechanical performance and accelerating patient
recovery. Furthermore, in automotive and consumer electronics sectors, AM
empowers designers to innovate rapidly, iterating on lattice designs to achieve
optimal performance and functionality.

Beyond its technical capabilities, AM democratizes manufacturing,

providing accessibility to small and medium-sized enterprises and fostering a
culture of innovation and collaboration. With desktop AM systems becoming
increasingly affordable and user-friendly, designers and engineers can explore
the limitless possibilities of lattice structure design without the constraints of
traditional manufacturing processes.

Additive Manufacturing revolutionizes lattice structure fabrication,

offering unprecedented freedom, flexibility, and efficiency in translating
intricate designs into physical prototypes. Through careful consideration of AM
parameters and leveraging advanced techniques such as SLS and FDM,
engineers can realize complex lattice structures with precision and accuracy.
This transformative technology not only accelerates innovation across industries
but also democratizes manufacturing, empowering designers to push the
boundaries of what is possible in lattice structure design and engineering.

5.6 EXPERIMENTAL VALIDATION:

Experimental validation constitutes a crucial phase in the development of

lattice structures, serving to corroborate theoretical predictions and refine
designs for real-world applications. This multifaceted process encompasses
several key steps, beginning with the fabrication of physical prototypes using
carefully selected materials and manufacturing techniques. These prototypes are

43
meticulously crafted to mirror the intricacies of their digital counterparts,
ensuring an accurate representation of the intended design.

Once fabricated, the prototypes undergo a battery of rigorous

experimental tests designed to assess their mechanical properties and validate
the predictions generated by Finite Element Analysis (FEA). Quasi-static and
dynamic impact tests are particularly instrumental in evaluating the energy
absorption performance of lattice structures. Through these tests, engineers
measure parameters such as force-displacement curves, absorbed energy, and
failure modes, providing invaluable insights into the structural behavior of
lattice structures under varying loading conditions.

The data obtained from experimental testing serves as a critical

benchmark for validating the accuracy and reliability of computational models.
By comparing experimental results with simulation data, engineers can assess
the predictive capabilities of FEA and identify any discrepancies between
theoretical predictions and real-world performance. This iterative process
enables engineers to refine and fine-tune computational models, ensuring that
they accurately capture the complex behaviors exhibited by lattice structures in
practical scenarios.

Moreover, experimental validation plays a pivotal role in bolstering

confidence in the applicability of lattice structures across diverse engineering
applications. By demonstrating the structural integrity and performance of
lattice prototypes under real-world conditions, engineers can validate their
suitability for a wide range of uses, from aerospace components to automotive
chassis and beyond. This validation process not only provides crucial feedback
for further design refinement and optimization but also instills trust in the
reliability and effectiveness of lattice structures as viable engineering solutions.

44
 Furthermore, experimental validation serves as a means of bridging the
gap between theory and practice, offering tangible evidence of the efficacy of
lattice structures in meeting design requirements and performance objectives.
Through meticulous experimentation and analysis, engineers can gain a deeper
understanding of the underlying mechanisms governing the behavior of lattice
structures, paving the way for continued innovation and advancement in lattice
structure design and engineering.

Experimental validation represents a cornerstone of the design and

development process for lattice structures, providing essential verification of
theoretical predictions and validation of computational models. Through a
combination of rigorous testing, meticulous analysis, and iterative refinement,
engineers can ensure the reliability, performance, and applicability of lattice
structures across a diverse array of engineering applications. By bridging the
gap between theory and practice, experimental validation serves as a catalyst for
innovation and advancement in lattice structure design, enabling engineers to
push the boundaries of what is achievable in modern engineering.

5.7 DATA ANALYSIS:

Data analysis represents a pivotal phase in the evaluation of lattice

structures, where experimental and simulation data converge to provide
comprehensive insights into their energy absorption behavior. Engineers
undertake a meticulous examination of both datasets, scrutinizing trends,
correlations, and trade-offs between various design parameters and performance
metrics. This exhaustive analysis offers a deeper understanding of the complex
relationships governing the behavior of lattice structures under diverse loading
conditions, enabling engineers to make informed decisions in design
optimization efforts.

45
 Experimental findings serve as a crucial benchmark for validating and
refining computational models, ensuring their accuracy and reliability in
predicting real-world performance. By comparing experimental results with
simulation data, engineers can identify any disparities and iteratively refine
computational models to better align with observed behaviors. Through this
iterative refinement process, the predictive capabilities of simulations are
enhanced, bolstering confidence in their applicability for optimizing lattice
structure designs.

Moreover, data analysis facilitates the identification of key insights and

trends that inform future design iterations and optimization strategies. By
uncovering correlations between design parameters and performance metrics,
engineers can identify opportunities for improving energy absorption efficiency
while minimizing material usage and manufacturing costs. This iterative
approach to data analysis empowers engineers to iteratively refine lattice
structure designs, ensuring optimal performance across a range of applications.

Furthermore, the synergistic integration of experimental validation and

computational modeling enables engineers to gain a deeper understanding of the
performance characteristics of lattice structures. By leveraging both datasets,
engineers can validate theoretical assumptions and refine design parameters to
achieve desired performance outcomes. This iterative process fosters continuous
improvement and innovation in lattice structure design, pushing the boundaries
of what is achievable in modern engineering practice.

In conclusion, data analysis represents a critical component of the design

and optimization process for lattice structures, offering valuable insights into
their energy absorption behavior and performance characteristics. By
meticulously examining experimental and simulation data, engineers can refine
computational models, optimize design parameters, and inform future design

46
iterations, ultimately enhancing the efficiency, reliability, and applicability of
lattice structures across a diverse range of engineering applications.

47
 CHAPTER 6

LIMITATIONS

 One limitation in this study could be the challenge of accurately

replicating complex lattice geometries through 3D printing, leading to
potential discrepancies between simulated and actual structural behavior.
 Variability in material properties and printing parameters may also affect
the reliability and consistency of energy absorption characteristics.
 Additionally, the scalability of 3D printing for producing large-scale
lattice structures and the associated cost implications might restrict the
practical implementation of findings.
 Ensuring precise control over printing processes and thorough validation
against experimental results are essential to mitigate these limitations and
enhance the applicability of the study's findings.

48
 CHAPTER 7

THREE DIMENSIONAL DIAGRAM

This Chapter deals with isometric view and part diagrams of Parts.

This designing software provides different approaches to generate a

model like parts design, surface design and assembling etc by allowing the user
to employ the combination of methods to create a modelling. The modelling
application also provides “feature based” solid bodies by directing editing
capabilities, which to change and update solid bodies by direct editing the
dimensions of solid feature or by using other geometric construction technique.

The various steps to create the model by using design software package are

Getting a 3-D Sketch of Model Operation carried out in software Package is

 Sketching
 Extruding
 Revolving
 Dimensioning

49
7.1 DIAGRAM

Figure 7.1 Diagram

7.2 IMAGE

Figure 7.2 Image

50
7.3 CUT SECTION OF ASSEMBLY

Figure 7.3 Cut Section Of Assembly

7.4 ASSEMBLY

Figure 7.4 Assembly

51
 CHAPTER 8

STRESS ANALYSIS

A stress that results from a slowly applied load and which does not involve
any acceleration forces.

8.1 ISOMETRIC VIEW REPORT

The isometric view report showcases the stress analysis findings of the
lattice structure constructed from TPU. With an average stress value of 12.131
MPa, the report indicates the structure's ability to efficiently distribute and
absorb energy. This attribute renders it well-suited for applications necessitating
impact resistance and deformation control. By effectively managing stress
distribution, the TPU lattice demonstrates its capacity to withstand applied loads
while maintaining structural integrity.

The stress distribution analysis serves as a crucial validation tool, affirming

the reliability and performance of the TPU lattice in real-world scenarios. By
comprehensively evaluating stress patterns throughout the structure, engineers
can ascertain its ability to withstand varying loads and environmental
conditions.

This validation process instills confidence in the structural design, ensuring

that it meets stringent performance requirements. Moreover, the stress analysis
findings provide valuable insights for further optimization efforts. By
identifying areas of high stress concentration, engineers can refine the lattice
design to enhance its overall performance and durability. This iterative approach
ensures that the TPU lattice remains at the forefront of engineering innovation,
continually evolving to meet the evolving demands of modern applications.

52
 Figure 8.1 Isometric View Report

8.2 FRONT VIEW

A front view static stress report offers a detailed analysis of stress

distribution across the frontal surface of a structure under static loading
conditions. This report provides crucial insights into the structural integrity and
performance of the design, highlighting areas of stress concentratio
concentration and
potential vulnerabilities. Through color-coded
color coded visualizations and numerical
data, engineers can assess stress levels at specific points or regions of interest,
aiding in the identification of critical areas that may require reinforcement or
optimization.
ion. By scrutinizing the static stress report, designers can make
informed decisions to enhance the robustness and reliability of the structure,
ensuring that it can withstand applied loads without compromising safety or
performance. This comprehensive ana
analysis
lysis serves as a valuable tool in the
design validation process, enabling engineers to validate their designs and
optimize structural performance effectively.

53
 Figure 8.2 Front View

8.3 SIDE VIEW

A side view static stress report provides a comprehensive analysis of stress

distribution along the lateral or side
side-facing
facing surface of a structure under static
loading conditions. This report offers valuable insights into the structural
behavior and integrity, illustrating stress concentrations and potential
potential areas of
concern. Through color-coded
coded visualizations and numerical data, engineers can
evaluate stress levels at specific locations along the side view of the structure,
facilitating the identification of critical regions that may require further analysis
or optimization. By scrutinizing the side view static stress report, designers can
make informed decisions to enhance the structural robustness and ensure that
the design can withstand applied loads effectively. This detailed analysis serves
as a crucial component of the design validation process, enabling engineers to
verify the structural performance and reliability of their designs accurately.

Figure 8.3 Side View

54
8.4 RESULTS

The utilization of TPU material in lattice structures yields promising

results, with the maximum stress reaching 12MPa. This finding underscores
TPU's suitability for absorbing impact and dissipating energy effectively within
lattice structures.

The observed stress level suggests that TPU exhibits robust energy
dissipation capabilities, positioning it as a viable material choice for
applications necessitating controlled deformation and resilience to external
forces. The 12MPa stress value attained highlights TPU's ability to withstand
varying loads and environmental conditions, thereby enhancing the structural
integrity and performance of lattice structures.

This reinforces TPU's potential across a diverse range of industries,

including automotive, aerospace, sports equipment, and protective gear, where
impact resistance and energy absorption are paramount. Furthermore, the results
affirm TPU's versatility and adaptability in engineering applications,
showcasing its ability to meet stringent performance requirements while
offering cost-effective and manufacturable solutions.

As such, the utilization of TPU in lattice structures presents a promising

avenue for enhancing product performance, durability, and safety, ultimately
contributing to advancements in engineering design and innovation.

55
 Figure 8.4 Results

8.4.1 Final Output

The final product model titled "Design and Analysis of Energy

Absorption Influenced Lattice Structures" is a comprehensive study that delves
into the intricate process of designing lattice structures optimized ffor efficient
energy absorption.

The study begins by addressing the growing demand for lightweight yet
resilient materials across industries and highlights the critical role that lattice
structuress can play in meeting this need. The primary objective is to explore
various design methodologies and conduct thorough analyses to propose
innovative lattice configurations that excel in absorbing energy. One of the key
design methodologies employed in the study is topology optimization. This
involves using advanced algorithms to determine the optimal distribution of
materials within the lattice structure, with the aim of maximizing energy
dissipation while minimizing weight. By striking a balance between structural
s
integrity and energy-absorbing
absorbing capabilities, topology optimization enables the
creation of highly
ghly efficient lattice designs.

56
 Figure 8.4.1 Final Output Of Lattice Design

In addition to topology optimization, the study also explores parameterized

parameterize
design techniques. These techniques allow for the systematic exploration of
design variables such as cell geometry, strut dimensions, and lattice density. By
systematically varying these parameters, researchers can identify the most
effective configurations
ons for energy absorption. Moreover, the study draws
inspiration from nature through biomimicry. By emulating natural structures
such as trabecular bone or plant cell configurations, researchers aim to optimize
energy absorption within lattice structures. This approach leverages the inherent
efficiency of natural systems to inform the design of synthetic materials. To
evaluate the performance of the designed lattice structures, the study employs
finite element analysis (FEA). FEA allows researchers to simul
simulate
ate the structural
behavior of lattice structures under various loading conditions, including
impacts, compression, and bending. Through FEA, researchers analyze key
parameters such as stress distribution, deformation patterns, and energy
absorption capacities,
ties, providing valuable insights into the effectivenes
effectiveness of
different lattice designs.

Finally, the study concludes with optimization techniques aimed at refining

the design of lattice structures for maximal energy absorption efficiency. By
iteratively fine-tuning
tuning design parameters based on insights gained from
57
mechanical analyses, researchers propose optimized lattice configurations
capable of meeting the demanding requirements of real-world applications.

8.5 MAXIMUM RANGE OF STATIC ANALYSIS

The maximum range of static analysis is encapsulated in this

comprehensive flowchart, delineating a systematic methodology from
inception to documentation. Commencing with a thorough literature review,
researchers embark on a journey of iterative design and analysis. Each step,
intricately interconnected, underscores the holistic nature of the process.
Beginning with the assimilation of existing knowledge, researchers delve
into conceptualization, surveying pertinent literature to inform subsequent
stages.

Design development unfolds, guided by insights gleaned from the

literature, paving the way for prototype creation. Through computational
modeling and experimental validation, the efficacy of lattice structures for
energy absorption is rigorously evaluated.

The flowchart underscores the iterative nature of the process, wherein

findings inform subsequent iterations, ensuring continual refinement.
Sensitivity analyses elucidate the influence of design parameters, guiding
optimization efforts to enhance energy absorption capabilities.

Ultimately, the culmination of this methodical approach is the

documentation and reporting of findings. By adhering to this structured
framework, researchers ensure a comprehensive and systematic progression
through the methodology.

This facilitates the design of highly effective lattice structures tailored for
optimal energy absorption, positioning them as indispensable components
across various engineering applications.

58
Figure 8.5 Maximum Range of Static Analysis

59
 CHAPTER 9

CONCLUSION

This study delves into the comprehensive exploration of lattice structures,

specifically targeting their capacity for energy absorption. Through a meticulous
approach encompassing design, analysis, and experimental validation, it aims to
uncover the intricate dynamics governing these structures. Utilizing advanced
computational techniques such as Finite Element Analysis (FEA), the study
predicts the mechanical response of lattice structures under diverse conditions.
FEA serves as a powerful tool in simulating and analyzing deformation patterns
and stress distributions, offering invaluable insights into the structures' energy
absorption behavior. Furthermore, optimization algorithms, notably topology
optimization, are employed to maximize the energy absorption efficiency of
lattice structures. By iteratively refining the design parameters based on
predefined criteria, these algorithms facilitate the creation of highly efficient
structural configurations tailored to specific engineering needs. Crucially, the
accuracy and reliability of computational models are validated through
empirical testing. Physical prototypes of the optimized lattice structures undergo
rigorous testing, confirming their enhanced energy absorption capabilities and
validating the efficacy of computational predictions. Overall, this research
contributes significantly to the advancement of lattice structure design and
analysis. By enhancing energy absorption capabilities through the integration of
computational modeling, optimization techniques, and experimental validation,
the study provides a solid foundation for the development of more efficient and
reliable lattice structures across a spectrum of engineering applications. From
automotive safety systems to aerospace structures and beyond, the insights
gleaned from this research hold the potential to revolutionize the design
landscape, ushering in a new era of enhanced performance and functionality in
lattice structures.
60
 CHAPTER 10
PROJECT OUTCOME

The following outcomes are attained through the project “Design and analysis
of energy absorption influenced lattice structures”

Project
Knowledge Relevance on Work Carried
outcome Project Outcomes Expected
Level Out
No.
The problem originated
with the heat dissipation
issue which was found in
Identifying a potential
1. foam as it does not contains
Problem based on literature
uniform structure. Thus our
survey/impending industrial/
K4 project focuses on designing
real time needs
a lattice that has a uniform
structure for better heat
dissipation.
Categorizing various
Various journals were
2. K4
solutions methodologies to
referred to solve the
Solve problem taken for study
problem.

Carry A Lattice structure is

3. outdesign/experimental K5 designed based on the

procedure relevant to the requirements and it is

problem. optimized

The design of lattice is

Analyze the design and
4. K5 finalized and the
experimental result

61
 experimental tests were
done.

Draw conclusion based on The newly designed lattice

analysis and recommended structure significantly
5. K5
solution to potential impact in energy absorption
Engineering problems and has better performance
standards

Program Outcome relevance to the project

PO1: Engineering Knowledge:
This project helps us to understand the topics such as CAD
modelling, FEA and 3D printing during the design, analysis and
fabrication process.
PO2: Problem analysis:
Heat dissipation issue which was found in foam is a main concern as it
does not contain a uniform structure. Thus our project focuses on designing a
lattice that has a uniform structure for better heat dissipation.
PO3: Design &Development of solutions:

In order to provide solution to the above issue, A new lattice

structure has been designed and analyzed which impacts is better energy
absorption and heat dissipation.
PO4: Conduct investigations of complex problems

The stress and compression of the fluid when in action are analyzed using
the simulation softwares.

PO5: Modern tool usage

3D printing methodology is used to print the final prototype lattice

62
structure.
PO6: The Engineer and Society:

I have gained knowledge on solving environmental issues by

doing this project. Had an exposure to solve the social complications
with the knowledge of engineering.
PO7: Environmental and sustainability:

The proposed lattice structure will have good economic

sustainability among the competitors.
PO8: Ethics:

This project had been performed to ensure the comfort and performance
for the individuals in the environment.

PO9: Individual and teamwork:

We have worked with dedication and cooperation to complete this
project successfully.
PO10: Communications:

We had taken assistance from the faculties and regularized meetings are
conducted for the completion of project.

PO11: Project management and finance:

We have allocated the works among us eventually and we have shared

the expenses equally for the outcome.

PO12: Lifelong learning:

 To apply my problem analysis knowledge in various sectors.

 To improve problem-solving skills in various sectors.

63
PSO1: Graduates will be able to create and analyse the Research and
Development activities related to design and manufacturing

The project was carried out through design and development of lattice
structure using 3D printing methodology of advanced manufacturing which
satisfies the PSO1 criteria

PSO2: Graduates will be able to design, develop need based products in

Mechanical Engineering and allied Industries.

The project was developed based on the present needs in the industry
using 3D printing thus satisfying the criteria of PSO2

64
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