A fast, efficient direct slicing method for slender member structures

This work describes a method for quickly and efficiently slicing structures consisting of a large number of slender members called struts connected at node positions called joints. Previous research on periodic lattice structures shows these structures are highly mechanically efficient with exceptionally high stiffness- and strength-to-weight ratios. Additive manufacturing technologies allow the construction slender member structures with complicated macroscale shapes. These structures could consist of thousands or millions of geometric primitives describing the struts. Structures with large numbers of geometric objects cause the conventional methods for manipulating, storing, and slicing the geometry of these parts via STL files to be highly inefficient. This work describes an alternate design process for slender member structures using efficient methods for manipulating, storing, and slicing the geometry of the part. These new methods, in particular a fast, efficient direct slicing method, enable printing slender member structures with over one hundred thousand struts. The slicing algorithm is nearly perfectly parallel so it could extend to handle structures with over one million struts, helping to facilitate the adoption of slender member structures for engineering-scale applications.