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Laser sintering of polyamide lattice-based lightweight fairing components for subsequent racetrack testing requires a high quality and a reliable design. Hence, the purpose of this study was to develop a design methodology for such additively manufactured prototypes, considering efficient generation and structural simulation of boundary conformal non-periodic lattices, optimization of production parameters as well as experimental validation.

Multi-curved, sandwich structure-based demonstrators were designed, simulated and experimentally tested with boundary conformal lattice cells. The demonstrator’s non-periodic lattice cells were simplified by forward homogenization processes. To represent the stiffness of the top and bottom face sheet, constant isotropic and mapped transversely isotropic simulation approaches were compared. The dimensional accuracy of lattice cells and demonstrators were measured with a gauge caliper and a three-dimensional scanning system. The optimized process parameters for lattice structures were transferred onto a large volume laser sintering system. The stiffness of each finite element analysis was verified by an experimental test setup including a digital image correlation system.

The stiffness prediction of the mapped was superior to the constant approach and underestimated the test results with −6.5%. Using a full scale fairing the applicability of the development process was successfully demonstrated.

The design approach elaborated in this research covers aspects from efficient geometry generation over structural simulation to experimental testing of produced parts. This methodology is not only relevant in the context of motor sports but is transferrable for all additively manufactured large scale components featuring a complex lattice sub-structure and is, therefore, relevant across industries.

Giant orthogonal grid barrel vault is generated by deleting members in the inessential force transfer path of the two-layer lattice barrel vault. Consisting of members in the essential transfer path only, giant orthogonal grid barrel vault is a new type of structure with clear mechanical behavior and efficient material utilization. The paper aims to discuss this issue.

The geometrical configuration of this structure is analyzed, and the geometrical modeling method is proposed. When necessary parameters are determined, such as the structural span, length, vault rise, longitudinal and lateral giant grid number and section height to top chord length ratio of the lattice member, the structure geometrical model can be generated.

Numerical models of giant orthogonal grid barrel vaults with different rise–span ratios are built using the member model that can simulate the pre-buckling and post-buckling behavior. So the possible member buckle-straighten process and the plastic hinge form–disappear process of the structure under strong earthquake can be simulated.

Seismic analysis results indicate that when the structure damages under strong earthquake there are a large number of buckling members and few endpoint plastic hinges in the structure. Dynamic damage of giant orthogonal grid barrel vault under strong earthquake is caused by buckling members that weaken the structural bearing capacity.

The rostrum of a paddlefish provides hydrodynamic stability during feeding process in addition to detect the food using receptors that are randomly distributed in the rostrum. The exterior tissue of the rostrum covers the cartilage that surrounds the bones forming interlocking star shaped bones.

The aim of this work is to assess the mechanical behavior of four finite element models varying the type of formulation as follows: linear-reduced integration, linear-full integration, quadratic-reduced integration and quadratic-full integration. The paper also presents the load transfer mechanisms of the bone structure of the rostrum. The base material used in the study was steel with elastic–plastic behavior as a homogeneous material before applying materials properties that represents the behavior of bones, cartilages and tissues.

Conclusions are based on comparison among the four models. There is no significant difference between integration orders for similar type of elements. Quadratic-reduced integration formulation resulted in lower structural stiffness compared with linear formulation as seen by higher displacements and stresses than using linearly formulated elements. It is concluded that second-order elements with reduced integration are the alternative to analyze biological structures as they can better adapt to the complex natural contours and can model accurately stress concentrations and distributions without over stiffening their general response.

The use of advanced computational mechanics techniques to analyze the complex geometry and components of the paddlefish rostrum provides a viable avenue to gain fundamental understanding of the proper finite element formulation needed to successfully obtain the system behavior and hot spot locations.

The purpose of this paper is to gain a better understanding on how metasurfaces behave, in terms of currents in each unit cell. A better knowledge of their behavior could lead to an ad-hoc design for specific applications.

The methodology used is both theoretical and numerical; it is based on circuit theory and on an optimization procedure.

The results show that when the knowledge of the current in each unit cell of a metasurface is needed, the most common approximations currently used are often not accurate. Furthermore, a procedure for the termination of a metasurface, with application-driven goals, is given.

This paper investigates the distribution of the currents in a 2D metamaterial realized with magnetically coupled resonant coils. Different models for the analysis of these structures are illustrated, and the effects of the approximations they introduce on the current values are shown and discussed. Furthermore, proper terminations of the resonators on the boundaries have been investigated by implementing a numerical optimization procedure with the purpose of achieving a uniform distribution of the resonator currents. The results show that the behavior of a metasurface (in terms of currents in each single resonator) depends on different properties; as a consequence, their design is not a trivial task and is dependent on the specific applications they are designed for. A design strategy, with lumped impedance termination, is here proposed.

Thus, in this work the goal is to design, simulate and optimise a holder of a brushless motor in lattice structure to get the best performance in terms of mechanical strength, vibration absorption and lightness.

Nowadays, most manufacturers and designers' goal are to sell efficient products in mass to keep up or outrun competition. Medical, aeronautical, automobile and civil engineering sectors produce complex parts and products that encompasses multiple properties such as lightweight, energy absorbance, vibration reduction and stress resistant. Studies found that lattice structures are more and more useful in these fields since their characteristics satisfy complex behaviour.

The study's outcome suggests that the use of lattice structure reduces 60% of the actual motor holder mass while keeping the strength of the material, meeting initial specifications.

The Ram capacity of the PC.

Light materials for aerospace engineering elongate the range of the unmanned aerial vehicle (UAV) to an extra range of flight.

Situation awareness of the country border using surveillance drone and minimising the consumption of fuel.

The research allowed reducing 60% the actual holder mass.

This study aims to investigate the behaviour of soft lattices, i.e. lattices capable of reaching large deformations, and the influence of the printing process on it. The authors focused on two cell topologies, the body-centred cubic (BCC) and the Kelvin, characterized by a bending-dominated behaviour relevant to the design of energy-absorbing applications.

The authors analysed the experimental and numerical behaviour of multiple BCC and Kelvin structures. The authors designed homogenous and graded arrays of different dimensions. The authors compared their technical feasibility with two three-dimensional-printed technologies, such as the fused filament fabrication and the selective laser sintering, choosing thermoplastic polyurethane as the base material.

The results demonstrate that multiple design aspects determine how the printing process influences the behaviour of soft lattices. Besides, a graded distribution of the material could contribute to fine-tuning this behaviour and mitigating the influence of the printing process.

Despite being less explored than their rigid counterpart, soft lattices are now becoming of great interest, especially when lightweight, wearable and customizable solutions are needed. This study contributes to filling this gap.

Only a few studies analyse design and printing issues of soft lattices due to the intrinsic complexity of printing flexible materials.

Molecular dynamics is an emerging simulation technique in the field of machining in recent years. Many researchers have tried to simulate different processing methods of various materials with the theory of molecular dynamics (MD), and some preliminary conclusions have been obtained. However, the application of MD simulation is more limited compared with traditional finite element model (FEM) simulation technique due to the complex modeling approach and long computation time. Therefore, more studies on the MD simulations are required to provide a reliable theoretical basis for the nanoscale interpretation of grinding process. This study investigates the crystal structures, dislocations, force, temperature and subsurface damage (SSD) in the grinding of iron-nickel alloy using MD analysis.

In this study the simulation model is established on the basis of the workpiece and single cubic boron nitride (CBN) grit with embedded atom method and Morse potentials describing the forces and energies between different atoms. The effects of grinding parameters on the material microstructure are studied based on the simulation results.

When CBN grit goes through one of the grains, the arrangement of atoms within the grain will be disordered, but other grains will not be easily deformed due to the protection of the grain boundaries. Higher grinding speed and larger cutting depth can cause greater impact of grit on the atoms, and more body-centered cubic (BCC) structures will be destroyed. The dislocations will appear in grain boundaries due to the rearrangement of atoms in grinding. The increase of grinding speed results in the more transformation from BCC to amorphous structures.

This study is aimed to study the grinding of Fe-Ni alloy (maraging steel) with single grit through MD simulation method, and to reveal the microstructure evolution within the affected range of SSD layer in the workpiece. The simulation model of polycrystalline structure of Fe-Ni maraging steel and grinding process of single CBN grit is constructed based on the Voronoi algorithm. The atomic accumulation, transformation of crystal structures, evolution of dislocations as well as the generation of SSD are discussed according to the simulation results.

The “chiralisation” of Euclidean polygonal tessellations is a novel, recent method which has been used to design new auxetic metamaterials with complex topologies and improved geometric versatility over traditional chiral honeycombs. This paper aims to design and manufacture chiral honeycombs representative of four distinct classes of 2D Euclidean tessellations with hexagonal rotational symmetry using fused-deposition additive manufacturing and experimentally analysed the mechanical properties and failure modes of these metamaterials.

Finite Element simulations were also used to study the high-strain compressive performance of these systems under both periodic boundary conditions and realistic, finite conditions. Experimental uniaxial compressive loading tests were applied to additively manufactured prototypes and digital image correlation was used to measure the Poisson’s ratio and analyse the deformation behaviour of these systems.

The results obtained demonstrate that these systems have the ability to exhibit a wide range of Poisson’s ratios (positive, quasi-zero and negative values) and stiffnesses as well as unusual failure modes characterised by a sequential layer-by-layer collapse of specific, non-adjacent ligaments. These findings provide useful insights on the mechanical properties and deformation behaviours of this new class of metamaterials and indicate that these chiral honeycombs could potentially possess anomalous characteristics which are not commonly found in traditional chiral metamaterials based on regular monohedral tilings.

To the best of the authors’ knowledge, the authors have analysed for the first time the high strain behaviour and failure modes of chiral metamaterials based on Euclidean multi-polygonal tessellations.

The paper targets on providing new experimental data for validation of the well-established mathematical models within the framework of the lattice Boltzmann method (LBM), which are applied to problems of casting processes in complex mould cavities.

An experimental campaign aiming at the free-surface flow within a system of narrow channels is designed and executed under well-controlled laboratory conditions. An in-house lattice Boltzmann solver is implemented. Its algorithm is described in detail and its performance is tested thoroughly using both the newly recorded experimental data and well-known analytical benchmark tests.

The benchmark tests prove the ability of the implemented algorithm to provide a reliable solution when the surface tension effects become dominant. The convergence of the implemented method is assessed. The two new experimentally studied problems are resolved well by simulations using a coarse computational grid.

A detailed set of original experimental data for validation of computational schemes for simulations of free-surface gravity-driven flow within a system of narrow channels is presented.