Renato Picelli, Scott Townsend, H. Alicia Kim
J. Mech. Des. Nov 2020, 142(11): 111705
https://doi.org/10.1115/1.4047152

The shape optimization of microstructural cells is investigated in this paper. Microstructure optimization yields the design of an architected material with a desired material property. Material usage and cost can be reduced by inserting holes into the microstructure. However, depending on the hole shape, the macroscale structure can fail because of the mechanical stress observed in the microstructural cell. This work investigates the possible stresses present in a microstructure and explores how shape optimization can be used for obtaining improved (optimal or nearly-optimal) cell configurations that have lower mechanical stress. The mechanical (von Mises) stress is evaluated using the finite element method. Cell shape optimization using mathematical programming is achieved using the level set method. As a result of this study, engineers have greater insight about, and flexibility when, designing microstructures.