The Design of Optimal Lattice Structures Manufactured by Maypole Braiding

Beginning with the maypole braiding process and its inherent constraints, we develop a design methodology for the realization of optimal braided composite lattice structures. This process requires novel geometric, mechanical, and optimization procedures for comprehensive design-ability, while taking full advantage of the capabilities of maypole braiding. The composite lattice structures are braided using yarns comprised of multiple prepreg carbon fiber (CF) tows that are themselves consolidated in a thin braided jacket to maintain round cross sections. Results show that optimal lattice-structure tubes provide significant improvement over smooth-walled CF tubes and nonoptimal lattices in torsion and bending, while maintaining comparable axial stiffness (AE).