Bioinspired lightweight product design involves complex geometries that are difficult to be made with traditional manufacturing processes. A unique way to create such complex geometries is through additive manufacturing. The overall objective of this research is to take a systems approach for the design of lightweight structure material systems. The system approach consists of four dimensions including unit structures, functionality, material layers, and physical properties. A case study is conducted based on aux, balsa wood, and auxetic structures for the lightweight material design. 3D model tests (e.g. finite element analysis and sustainability analysis) and physical tests are conducted on the developed materials and served for target purposes. The results of this research offers new insights into the design, manufacture and application of smart lightweight structures in engineering fields and contributes to the engineering management by providing a systems engineering approach to the lightweight material structure design realm.

Authors: Owen Gagnon, Brenton Whanger, Hao Zhang, Ji XU