Develop Optimized Bridge Connections with Additively Manufactured Lattice Structures (DOCAM)

A critical design challenge in bridge and other large structures is the connection parts. To achieve required structural robustness, the final connection design often ends up with a large amount of wasted material, which significantly increase raw material costs. Additionally, for military bridge connection designs with small production volume in particular, traditional manufacturing approaches are often time-consuming and cost-ineffective. Therefore, it is imperative to find an alternative effective manufacturing approach that can address current issues on costs, as well as structural weight and performances. Intelligent Automation Inc. (IAI) proposes to resolve the critical challenges by combining numerical simulations, design optimization, and experimental testing with state-of-art Additive Manufacturing (AM) technologies. In this study, we will use numerical simulations and design optimization approach to derive optimized lightweight lattice connection designs with high strength and durability based on various loading conditions and given structural interfaces. We will also prove the manufacturability of the connection part using Additive Manufacturing technology and perform lab/field qualification tests. The methodology framework and software tools that we derive during this research effort can be applied to other important connection designs, such as joints for deployable large space structures.