Bio-inspired design, modeling, and 3D printing of lattice-based scale model scooter decks

Abstract

This research aims at enhancing the performance of scale-model scooter decks by investigating various architected cellular metamaterial and bio-inspired core structure designs, such as honeycomb, tetrachiral, re-entrant, arrowhead, and star-shaped arrangements. An initial effort is made toward the design and rapid prototyping of small-scale deck with a uniform honeycomb core structure. More specifically, polylactic acid is utilized to fabricate complex structures via fused filament fabrication technique. Investigation is then focused on its mechanical performance, such as its bending properties obtained through a three-point bending test. Simulations are also conducted with different core configurations using a geometrically non-linear finite element method which is implemented. Experiments are carried out to verify the numerical results. After validation, various patterns are modeled, and eventually, it is observed that the functionally graded arrowhead structure has the best bending resistance, compared to other bio-inspired and mechanical metamaterial structures. At a constant force of 845 N, the functionally graded arrowhead design lowers the deflection in the middle of the scale model of scooter deck by up to 14.7%, compared to the uniform arrowhead structure. Furthermore, comparing the tetrachiral and functionally graded arrowhead configurations at a constant force, a 30% reduction in central deflection was observed. Due to the lack of similar results and designs in the specialized literature, this work could potentially advance the state-of-the-art scooter core designs and provide designers with architectures that could enhance the performance and safety of scooters.

Flexural properties of porcupine quill-inspired sandwich panels

“…This observation is also reported by Zhao et al [53], where a 3D-graded irregular structure has better impact resistance than a regular structure. Meanwhile, graded structures have shown a promising mechanical performance over the non-graded structures [23]. Overall, first-degree graded structures perform better than non-graded and seconddegree graded structures.…”

“…Aiming to produce structures with high stiffness and weight ratio, sandwich panels are designed with low-density cores and thin skins [14]. Inspired by nature, various complex cores can be fabricated using FDM, including honeycomb, auxetic and a range of triply periodic minimal surface cellular [16][17][18][19][20][21][22][23]. Li et al [17] employed functionally graded design to design gyroid structures with varying densities.…”

Prioritization and deployment of design for additive manufacturing strategies to an automotive component

“…By considering all these limitations (Sossou et al , 2018; Wiberg et al , 2019; Zolfagharian et al , 2020; Namvar et al , 2023), distinctive approaches and strategies are needed for framing the framework where the product functionality is mainly applicable to automotive components where the objective may vary ranging from material characteristics, behavior, optimizing stress, factor of safety, weight reduction, material cost, printing cost and structural integrity to improve the performance. The SIMP method for TO is preferred in automotive applications for predicting an optimal material distribution within a given design space for given load cases, boundary conditions, manufacturing constraints and performance requirements.…”

“…The soft kill option (SKO) method is used as a TO technique due to the porous structure of materials. Namvar et al (2023) developed different bioinspired and architected metamaterial core structures as lattice designs and investigated their bending resistance by applying them to a scale model of a scooter deck. Various designs inspired by natural patterns and shapes were reentrant, tetrachiral, star-shaped, arrowhead and graded arrowhead structures.…”

Structural Performance of Additively Manufactured Composite Lattice Structures: Strain Rate, Cell Geometry, and Weight Ratio Effects

“…[1][2][3][4][5] Additive thinking is indeed infiltrating the scientific and technological communities, racing to realize the benefits of these empowering advanced manufacturing techniques in every industrial domain, from consumer goods to nutrient alternatives and extreme engineering such as space travel. [6][7][8][9] For example, sporting equipment, including protective helmets and running shoes, have been mass-produced using various additive manufacturing approaches, [6,7,10] enabling their retail to the general public at competitive prices. In short, the premises of additive manufacturing, such as broadening the design envelope, just-in-time delivery, and efficient production, are manifested in reallife applications and facilitate the rapid translation of products from the bench to the market.…”