| Zhang, Min, Liu, Jinlong, Li, Zeyang, Yang, Jie and Gao, Kang 2026. Multiscale Optimization of Manufacturable Multi-Variable Shell Lattices (MVSL) for enhanced mechanical performance. International Journal of Mechanical Sciences 320 , 111617. 10.1016/j.ijmecsci.2026.111617 |
Abstract
Shell-based metamaterials outperform conventional lattice structures in stiffness, energy absorption efficiency, and multifunctionality, with applications ranging from electromagnetic shielding to fluid transport. Yet existing designs paradigms are constrained by a finite repertoire of unit cells, primarily drawn from established triply periodic minimal surface (TPMS) families, which restricts geometric versatility. To overcome these constraints, we propose an intelligent optimization framework for multi-variable shell-based lattices (MVSL) that integrates manufacturing considerations while expanding design freedom. A library of manufacturable MVSL unit cells is first established through two-level connectivity and cavity constraints. This novel lattice architecture family demonstrates exceptional mechanical performance while enabling unprecedented decoupling between interfacial surface area and structural stiffness characteristics. Next, a combined topology optimization and dynamic clustering strategy then guides the spatial distribution of unit cells, while a hybrid deep neural network-genetic algorithm (DNN-GA) system, incorporating manufacturability penalties, efficiently maps target macroscopic properties to feasible microstructures. Finally, three numerical case studies validate the framework’s effectiveness. Experimental validations on additively manufactured prototypes demonstrate the optimized structures achieve 59.32% higher flexural stiffness and 21.48% increased strength compared to uniform single-cell arrays. This multiscale approach provides tailored solutions for multifunctional engineering applications, bone tissue scaffolds, acoustic metasurfaces, and heat management systems, bridging the gap between theoretical performance and manufacturable designs.
| Item Type: | Article |
|---|---|
| Date Type: | Publication |
| Status: | Published |
| Schools: | Schools > Engineering |
| Additional Information: | License information from Publisher: LICENSE 1: URL: http://creativecommons.org/licenses/by-nc-nd/4.0/, Start Date: 2028-04-24 |
| Publisher: | Elsevier |
| ISSN: | 0020-7403 |
| Date of Acceptance: | 10 April 2026 |
| Last Modified: | 05 May 2026 11:45 |
| URI: | https://orca.cardiff.ac.uk/id/eprint/186779 |
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