A novel design method for TPMS lattice structures with complex contour based on moving elements method

Over the past few decades, there have been many important achievements on the design, research, and development of minimal surface lattice structures. In this work, we propose a modeling method for triply periodic minimal surfaces (TPMS) lattice structures with complex contours. This method is based on moving elements method (MEM) and mainly includes the following parts: dividing the model mesh, solving the iso-surface of the TPMS in the model, obtaining the TPMS lattice structure triangular surface of the model outline, integrating the interior of the model and the outline, and finally generating an STL file that can be used for additive manufacturing. Furthermore, the representative femur model, rabbit model, and gear model are provided as case studies to verify the validity and correctness of the proposed modeling method. Then, this approach is compared with the distance field-based method (DFBM) in terms of modeling speed and modeling accuracy. The research results show that the time required by the MEM method was reduced by 3055.56%, 2799.70% compared to the DFBM method, when filling the network primitive and network gyroid lattice structures in the femur model. Moreover, this method provides technical means and simulation data for designing TPMS lattice structures with complex contour, and offers the underlying design ideas for the development and application of the excellent physical properties of TPMS lattice structures in medicine and engineering.