A new family of minimal surface-based lattice structures for material budget reduction

This article aims to describe a novel workflow designed for generating a new family of minimal surface-based lattice structures with improved performance in terms of material budget compared to the well-known cells like Gyroid and Schwartz. The implemented method is based on the iterative resolution of a dynamic model, where proper forces are applied to generate minimal surface lattices, considering the boundary conditions and the constraint configurations. The novelty of the approach is given by the ability to create a minimal surface without resolving the partial differential equation and without knowing the exact minimal surface generative function. The starting geometry used for the lattice generation is the hypercube, parametrized to create different lattice configurations. Creating five different starting geometries and two constraint configurations, ten different lattice cells were created. For the comparison, a representative parameter of the material budget has been introduced and used to define the two best cells. The material budget is crucial for particle accelerator components, sensors, and detectors. These cells have been compared with Gyroid and Schwartz of the same thickness and bounding box, highlighting improvements of a factor of 2.3 and 1.7, respectively, in terms of material budget. The same cells have also been 3D-printed and tested under compression, and the obtained force–displacement curves were compared with those from a finite element analysis, demonstrating good agreement in the elastic region.