A biomimetic design framework for structurally optimized lifting beams using graded geometry and internal ribs

Jacob Nagler

doi:10.59400/mea3582

A biomimetic design framework for structurally optimized lifting beams using graded geometry and internal ribs

Jacob Nagler
Nagler Independent Research Center (NIRC), Haifa 34345, Israel

Article ID: 3582

Keywords: biomimetic design, lifting beam, graded thickness, rib lattice, topology optimization, Timoshenko beam, additive manufacturing

Abstract

This paper presents a comprehensive biomimetic design framework for lifting beams that couples an exponentially graded outer shell with an internal dendritic rib network to maximize stiffness-to-weight performance while meeting serviceability and safety constraints. A multi-fidelity modelling chain is developed: a variable-section Euler–Bernoulli model for rapid sizing, a shear-corrected Timoshenko formulation for regimes in which transverse shear is significant, and a 2D arch-frame finite-element model that resolves local rib–shell interactions and stress concentrations. A density-based SIMP topology-optimization workflow is integrated with parametric regression to extract manufactural rib trajectories, and analytical closed-form expressions are derived for second moment contributions of graded shells and discrete ribs. Morphologically, the final optimized topology converges to a graded cellular arch frame resembling a chiropteran bat-wing, where the internal dendritic lattice functions as a variable-depth Warren truss to effectively decouple shear flow from the bending-dominated outer shell. Extensive analytical investigations: parametric sweeps, one-factor-at-a-time sensitivity, and first-order uncertainty propagation, demonstrate that graded thickness and load-path aligned ribs increase the section modulus and reduce peak bending demands; for representative baseline geometries and materials, the proposed topology yields ~20% reduction in peak bending stress and ~15% reduction in midspan deflection at equal mass compared with conventional solid sections. High-fidelity FEA highlights local saw-tooth stress peaks at rib roots that exceed mean analytical estimates by ≈60%, indicating the necessity of filleting, fatigue-aware detailing, and AM process control. The manuscript concludes with a rigorous experimental validation roadmap (AM prototyping, DIC, static and fatigue testing, CT/NDT) and recommends embedding uncertainty-aware surrogates and single-loop multidisciplinary optimization to ensure robust, certifiable lifting hardware under multi-source variability.

Published

2025-10-15

How to Cite

Nagler, J. (2025). A biomimetic design framework for structurally optimized lifting beams using graded geometry and internal ribs. Mechanical Engineering Advances, 3(4). https://doi.org/10.59400/mea3582

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Issue

Vol. 3 No. 4 (2025)

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Article

This work is licensed under a Creative Commons Attribution 4.0 International License.

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