Design for Additive Manufacturing of Lattice Structures for Functional Integration of Thermal Management and Shock Absorption

Design optimization through the integration of multiple functions into a single part is a highly effective strategy to reduce costs, simplify assembly, improve performance, and reduce weight. Additive manufacturing facilitates the production of complex structures by allowing parts consolidation, resulting in optimized designs, where multiple functions are integrated into a single component. This study presents a design for additive manufacturing method for integrating multiple lattice structures to achieve thermal management and shock absorption functions. The method follows modeling and simulation phases for dimensioning and optimizing solutions to deliver the design functions at different macro- and mesoscale levels. Hierarchical complexity was leveraged to design the two-levels structure in a single part, each delivering a specific function. Specifically, the external layer addresses energy absorption and thermal insulation, while the internal layer acts as a thermal battery by incorporating a phase change material. The design of a container carried by an unmanned aerial vehicle for the transport of healthcare and biological materials is presented. The container is shock-resistant and can maintain the content at 4 ± 2 °C for at least 1 h. As it operates passively without the need for additional energy-consuming devices, it is easy to operate and contributes to increased flight autonomy. A flight mission experiment for urgent transport of blood bags confirmed the capability of the container to preserve blood integrity. This case study demonstrates that the two-layer lattice structure design represents a highly efficient approach to multifunctional design optimization. © 2025 by the authors.