Surface modified unit cell lattice structures for optimized secure freeform fabrication

A method of preparing a computer-generated model of a three-dimensional structure constructed of porous geometries, the method comprising:

• preparing a computer-generated component file including a porous CAD volume having a boundary;
• populating, by a processor, a space including the porous CAD volume with unit cells on or overlapping the boundary;
• populating, by a processor, the unit cells with porous geometries, the porous geometries having a plurality of struts having opposing ends, each end being connected at a corresponding node, the plurality of struts including at least a first strut intersecting the boundary and having a length, a first node at a first location either (i) on the boundary or (ii) outside the porous CAD volume, and a second node at a second location either (i) on the boundary when the first node is outside the porous CAD volume or (ii) inside the porous CAD volume;
• and
• moving, by a processor, either (i) the first node from the first location to a third location or (ii) the second node from the second location to a fourth location.

A non-transitory computer-readable storage medium on which computer readable instructions of a program are stored, the instructions, when executed by a processor, cause the processor to perform a method of preparing a computer-generated model of a three-dimensional structure constructed of porous geometries, the method comprising:

• preparing a computer-generated component file including a porous CAD volume having a boundary;
• populating, by a processor, a space including the porous CAD volume with unit cells on or overlapping the boundary;
• populating, by a processor, the unit cells with porous geometries, the porous geometries having a plurality of struts having opposing ends, each end being connected at a corresponding node, the plurality of struts including at least a first strut intersecting the boundary and having a length, a first node at a first location either (i) on the boundary or (ii) outside the porous CAD volume, and a second node at a second location either (i) on the boundary when the first node is outside the porous CAD volume or (ii) inside the porous CAD volume;
• and
• moving, by a processor, either (i) the first node from the first location to a third location or (ii) the second node from the second location to a fourth location.

A method of preparing a computer-generated model of a three-dimensional structure constructed of porous geometries, the method comprising:

• preparing a computer-generated component file including a porous CAD volume having a boundary;
• populating, by a processor, a space including the porous CAD volume with unit cells on or overlapping the boundary;
• populating, by a processor, the unit cells with porous geometries, the porous geometries having a plurality of struts having opposing ends, each end being connected at a corresponding node, the plurality of struts including at least a first strut intersecting the boundary and having a length, a first node at a first location either (i) on the boundary or (ii) outside the porous CAD volume, and a second node at a second location either (i) on the boundary when the first node is outside the porous CAD volume or (ii) inside the porous CAD volume;
• and
• replacing, by a processor, either of (i) the first node with a first replacement node at a third location and (ii) the second node with a second replacement node at a fourth location.