Optimizing lightweight lattice structures through integrated parameterized design and fiber-reinforced additive manufacturing

Lattice structures offer advantages in load-bearing applications in terms of structural efficiency and strength-to-weight ratio. Previous structure optimization methods were mainly based on discretized structures without incorporating manufacturing capabilities, thus ad-hoc treatments or redesigns were required to enable fabrication. This paper presents a ‘rotation vector’ based method that parameterizes lattice structures and directly generates curved printing paths, which is particularly suitable for multi-axis additive manufacturing using fiber-reinforced filaments. The proposed method simultaneously considers structure-stress alignment and layer-wise fabrication to achieve optimized design with enhanced strength-to-weight ratio, which is parametrically adaptable to different printing configurations and infill densities.