A Computational Geometry Generation Method for Creating 3D Printed Composites and Porous Structures

A computational method for generating porous materials and composite structures was developed and implemented. The method is based on using 3D Voronoi cells to partition a defined space into segments. The topology of the segments can be controlled by controlling the Voronoi cell set. The geometries can be realized by additive manufacturing methods, and materials can be assigned to each segment. The geometries are generated and processed virtually. The macroscopic mechanical properties of the resulting structures can be tuned by controlling microstructural features. The method is implemented in generating porous and composite structures using polymer filaments i.e., polylactic acid (PLA), thermoplastic polyurethane (TPU) and nylon. The geometries are realized using commercially available double nozzle fusion deposition modelling (FDM) equipment. The compressive properties of the generated porous and composite configurations are tested quasi statically. The structures are either porous of a single material or composites of two materials that are geometrically intertwined. The method is used to produce and explore promising material combinations that could otherwise be difficult to mix. It is potentially applicable with a variety of additive manufacturing methods, size scales, and materials for a range of potential applications.