Nonlinear cellular structures are defined as structures with multiple scale unit cells patterned through the volume of the structure. The geometrical nonlinearity allows local high flexibility in the movement and also in the sense of strength of materials.

The focus of this paper is to create a framework for design for additive manufacturing (DfAM) of a modular nonlinear cellular structure with high level of flexibility. The flexibility will be exploited in skin-like structures adaptable to freeform geometries or utilize flat printed designs for voluminous and structural 3D shapes.

For the modeling of the structure CAD software is used and for the fabrication of the structure additive manufacturing (AM) is applied. These technologies work by adding the material in layers, which enables fabrication of parts with complex geometries. The working principal of AM which is opposite to the traditional manufacturing requires for changes in the design process. These changes are applied in the DfAM that we are presenting with this study. The DfAM is used to develop a systematic design approach to support the fabrication of unique structure shapes by AM.

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