Isomax™

A process for determining the geometry of a material that gives the lightest and most efficient space-filling design possible with highly optimized, functionally-graded structures for lightweight, high strength applications. It can be made from a variety of materials, including polylactic acid (PLA) derived from renewable resources. This geometry is unique in its properties, due to the symmetries and alignments of the base material, and its ability to achieve theoretical upper bounds for lightweight structural efficiency. The design is roughly 3x more efficient than the best lattice designs possible, and similarly outperforms honeycombs in terms of isotropic (omnidirectional) properties, resulting in extreme specific stiffness and very high specific strength (potentially maximal, too) over a wide range of (relative) densities, effectively ~10 kg/m3˜–2000 kg/m3 (0.62 lb/ft3–124.6 lb/ft3). As a low density cellular material, it can possess low thermal conductivity, low electrical conductivity, large crushing strains and energy absorption, buoyancy, fluid permeability and storage, vibration attenuation, and optical band gaps. Using sophisticated manufacturing techniques such as advanced 3D printing processes, it is possible to achieve much greater resolution, surface finish, and material properties in the final products. At this time, only bespoke parts are available and the manufacturer is working on scalable fabrication approaches. Standard size available is 50 mm x 50 mm x 50 mm (1.97 in x 1.97 in x 1.97 in) and the base material can be customized to achieve the desired performance. The most favorable materials are those with inherent high specific stiffness and strength, such as titanium and aluminum alloys, carbon fiber composites, and ceramics such as boron carbide and silicon carbide. Applications include any area where lightweight structures and materials are required, such as defense and commercial aerospace, civil engineering and construction, footwear, personal transportation and shipping, energy absorbing structures for vehicles and personal protection, sports equipment, medical devices, and unmanned aerial vehicles.