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Lattice structures, which consist of interconnected strut members in micro- and millimeter scales,
recently gained popularity to attain a lightweight structure while maintaining the high specific
mechanical properties such as strength and energy absorption. However, the application of lattice
structures for crash box designs has been rarely reported for 3D printing. The lattice cell
configurations used for designs are also standard configurations. This study presents a design
methodology that first generates a lightweight lattice cell design using a discrete topology
optimization process. The crash box geometry is then modeled using the designed lattice cells. Non-
linear compression simulations are performed to investigate the energy absorption capability of the
lattice designs by considering Nylon12 material fabricated by Multi Jet Fusion 3D printing technique.
The results are compared with the existing literature for validation. It has been observed that the
topology optimized lattice structures have good potential to be used as energy absorption devices
when fabricated by 3D printing.
International Congress on 3D Printing (Additive Manufacturing) Technologies and Digital Industry
3D-PTC2019
Recep M. Görgülüarslan
O. Utku Güngör
Saltuk Yıldız
Erdem Erem