System and method for generative design and additive manufacturing of non-newtonian smart materials for energy absorption

A system for designing and manufacturing non-Newtonian energy-absorbing structures, the system being configured to receive user-defined input parameters and to generate physical structures through an integrated design-to-fabrication workflow and comprising:

• a user interface configured to receive input parameters comprising material properties, loading conditions, and geometric constraints and to convert the input parameters into structured data;
• a generative design module configured to receive the structured data and to generate candidate structures using a 3D conditional diffusion model that synthesizes voxel-based geometries based on physical and rheological characteristics of a selected non-Newtonian material;
• a database configured to store a dataset comprising experimentally derived rheological data, comprising viscosity curves, viscoelastic moduli, and manufacturing parameters;
• the database is further configured to provide the stored dataset to the generative design module during generation to the candidate structures;
• and
• a finite element analysis (FEA) module configured to simulate mechanical performance of the candidate structures using material models specific to non-Newtonian behavior and a voxel mesh resolution consistent with an additive manufacturing process.