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

A critical design challenge in Armored Vehicle Launched Bridge (AVLB) is the connection parts. The critical structural robustness requirements lead to a large amount of wasted material in design, and small production volume using traditional manufacturing approaches is often time-consuming and cost-ineffective. 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 advanced modeling and optimization methods and state-of-art Additive Manufacturing (AM) technologies. In Phase II, we will advance our technologies based on wire arc AM (WAAM) applicable to large structure components. The research efforts include developing enhanced capabilities for modeling and optimization analysis, process modeling and control, and quality control measures. Further, we will derive lightweight lattice connection designs with high strength and durability based on various loading conditions and given structural interfaces, prototype sub-/full-scaled connections based on optimal process parameter sets, and conduct certification analysis and lab validation tests.