Ultra-strong 2-manifold panels based on biomimetic inspired, algorithmically optimized structures

Abstract

2-manifold structures are structures having continuously curvilinear surfaces, with no kinks or sharp angles. Methods for building strong, lightweight 2-manifold structures include a computer implemented strength optimization process. The computer implemented process includes a structure optimization sub-routine in which a plurality of rod-like members, constituting an irregular scaffold, is constrained into a volume corresponding to the 2-manifold structure. The strength of the irregular scaffold is then optimized by application of an algorithm that maximizes strength as a function of variations in the ratio of the largest macroscopic dimension of the panel to the average length of the members; the aspect ratio of the members (diameter divided by length); the average or maximum number of times a member can contact another member; and the distribution of member lengths. Strength maximization can be simultaneous to minimization of total length of the members. The process can includes additional compositional and structural optimizations, prior to fabrication of the irregular scaffold, and encasing of the scaffold in a shell, or infiltration of the scaffold with a matrix material.