Design for Additive Manufacturing of Lattice Structures for Functional Integration of Thermal Management and Shock Absorption
Design optimization through the integration of multiple functions into a single part is a highly effective strategy to reduce costs, simplify assembly, improve performance, and reduce weight. Additive manufacturing facilitates the production of complex structures by allowing parts consolidation, res...
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| Format: | Article |
| Language: | English |
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MDPI AG
2025-01-01
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| Series: | Journal of Manufacturing and Materials Processing |
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| Online Access: | https://www.mdpi.com/2504-4494/9/1/24 |
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| author | Enrico Dalpadulo Mattia Pollon Alberto Vergnano Francesco Leali |
| author_facet | Enrico Dalpadulo Mattia Pollon Alberto Vergnano Francesco Leali |
| author_sort | Enrico Dalpadulo |
| collection | DOAJ |
| description | Design optimization through the integration of multiple functions into a single part is a highly effective strategy to reduce costs, simplify assembly, improve performance, and reduce weight. Additive manufacturing facilitates the production of complex structures by allowing parts consolidation, resulting in optimized designs, where multiple functions are integrated into a single component. This study presents a design for additive manufacturing method for integrating multiple lattice structures to achieve thermal management and shock absorption functions. The method follows modeling and simulation phases for dimensioning and optimizing solutions to deliver the design functions at different macro- and mesoscale levels. Hierarchical complexity was leveraged to design the two-levels structure in a single part, each delivering a specific function. Specifically, the external layer addresses energy absorption and thermal insulation, while the internal layer acts as a thermal battery by incorporating a phase change material. The design of a container carried by an unmanned aerial vehicle for the transport of healthcare and biological materials is presented. The container is shock-resistant and can maintain the content at 4 ± 2 °C for at least 1 h. As it operates passively without the need for additional energy-consuming devices, it is easy to operate and contributes to increased flight autonomy. A flight mission experiment for urgent transport of blood bags confirmed the capability of the container to preserve blood integrity. This case study demonstrates that the two-layer lattice structure design represents a highly efficient approach to multifunctional design optimization. |
| format | Article |
| id | doaj-art-4565ec563ac8412b8dc5bb69ccaab8cb |
| institution | Kabale University |
| issn | 2504-4494 |
| language | English |
| publishDate | 2025-01-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Journal of Manufacturing and Materials Processing |
| spelling | doaj-art-4565ec563ac8412b8dc5bb69ccaab8cb2025-01-24T13:36:28ZengMDPI AGJournal of Manufacturing and Materials Processing2504-44942025-01-01912410.3390/jmmp9010024Design for Additive Manufacturing of Lattice Structures for Functional Integration of Thermal Management and Shock AbsorptionEnrico Dalpadulo0Mattia Pollon1Alberto Vergnano2Francesco Leali3“Enzo Ferrari” Department of Engineering, University of Modena and Reggio Emilia, 41125 Modena, Italy“Enzo Ferrari” Department of Engineering, University of Modena and Reggio Emilia, 41125 Modena, Italy“Enzo Ferrari” Department of Engineering, University of Modena and Reggio Emilia, 41125 Modena, Italy“Enzo Ferrari” Department of Engineering, University of Modena and Reggio Emilia, 41125 Modena, ItalyDesign optimization through the integration of multiple functions into a single part is a highly effective strategy to reduce costs, simplify assembly, improve performance, and reduce weight. Additive manufacturing facilitates the production of complex structures by allowing parts consolidation, resulting in optimized designs, where multiple functions are integrated into a single component. This study presents a design for additive manufacturing method for integrating multiple lattice structures to achieve thermal management and shock absorption functions. The method follows modeling and simulation phases for dimensioning and optimizing solutions to deliver the design functions at different macro- and mesoscale levels. Hierarchical complexity was leveraged to design the two-levels structure in a single part, each delivering a specific function. Specifically, the external layer addresses energy absorption and thermal insulation, while the internal layer acts as a thermal battery by incorporating a phase change material. The design of a container carried by an unmanned aerial vehicle for the transport of healthcare and biological materials is presented. The container is shock-resistant and can maintain the content at 4 ± 2 °C for at least 1 h. As it operates passively without the need for additional energy-consuming devices, it is easy to operate and contributes to increased flight autonomy. A flight mission experiment for urgent transport of blood bags confirmed the capability of the container to preserve blood integrity. This case study demonstrates that the two-layer lattice structure design represents a highly efficient approach to multifunctional design optimization.https://www.mdpi.com/2504-4494/9/1/24multi-scale designfunctional integrationimpact absorptionthermal insulationcellular structuretriply periodic minimal surface |
| spellingShingle | Enrico Dalpadulo Mattia Pollon Alberto Vergnano Francesco Leali Design for Additive Manufacturing of Lattice Structures for Functional Integration of Thermal Management and Shock Absorption Journal of Manufacturing and Materials Processing multi-scale design functional integration impact absorption thermal insulation cellular structure triply periodic minimal surface |
| title | Design for Additive Manufacturing of Lattice Structures for Functional Integration of Thermal Management and Shock Absorption |
| title_full | Design for Additive Manufacturing of Lattice Structures for Functional Integration of Thermal Management and Shock Absorption |
| title_fullStr | Design for Additive Manufacturing of Lattice Structures for Functional Integration of Thermal Management and Shock Absorption |
| title_full_unstemmed | Design for Additive Manufacturing of Lattice Structures for Functional Integration of Thermal Management and Shock Absorption |
| title_short | Design for Additive Manufacturing of Lattice Structures for Functional Integration of Thermal Management and Shock Absorption |
| title_sort | design for additive manufacturing of lattice structures for functional integration of thermal management and shock absorption |
| topic | multi-scale design functional integration impact absorption thermal insulation cellular structure triply periodic minimal surface |
| url | https://www.mdpi.com/2504-4494/9/1/24 |
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