The Size Matching and Scaling Method: A Synthesis Method for the Design of Mesoscale Cellular Structures

Mesoscale lattice structures are a type of cellular structure with support element lengths on the order of magnitude of centimeters. These types of structures are engineered for high performance and are used particularly in industries where low weight and high strength are desired. However, these structures are difficult to design because they often contain thousands of support elements. To design mesoscale lattice structures, current synthesis methods generally require some form of rigorous, multi-variable optimization that can slow or halt the design process. In this paper, we present a new, highly efficient, method for the design of mesoscale lattice structures, the Size Matching and Scaling method. This method eliminates the need for time-consuming optimization by using a combination of a solid-body finite element analysis and a library of pre-defined lattice configurations to generate a structure's lattice topology. In addition, we explore several methods for determining the best lattice diameter values for the lattice topology. Various 2-D and 3-D examples will be used to test and validate the method.