Additively manufactured mechanical components show great lightweight characteristics and can often be enhanced by integrating biomimetic geometrical features. This study focuses on one specific subcase, namely the substitution of solid cylindrical beams that are under bending with geometrically more complex biomimetic beams. Based on the pseudo-stem of the banana plant as a role model, six geometric beam designs were derived. Given the manufacturing constraints of the PBF-LB/M process, two abstractions were selected for detailed investigation in the main part of this study. The beam lengths were set to 100 mm. Based on parametric optimization simulations, optimal design parameters were identified for the two biomimetic abstractions for 26 different bending load cases ranging from 14 to 350 Nm. Analogous parameter optimizations were performed for a solid cylindrical beam design, which was used as a reference. The results provide detailed design solutions within the investigated intervals for biomimetic beams that can be substituted into more complex mechanical component designs with ease. The analysis provides information on which structures to use for the investigated loads. With the help of the developed numerical models, designers can easily generate biomimetic beam designs for specific bending load values.
Keywords: FEM; PBF-LB/M; additive manufacturing; beam structures; biomimetics; component design; lightweight design; parameter optimization; powder bed fusion.